Senior Director, Maintenance & Reliability

The Reliability and Maintenance Manufacturing Lead is responsible for ensuring the integrity, reliability, and safety of critical assets. In this role, you will utilize your experience and expertise to solve problems, develop and execute tactical & strategic objectives, and drive results that impact short-term and long-term business goals. You will be responsible for developing and implementing asset integrity management programs that drive operational excellence, reduce risk, and maximize asset life. This position works closely with cross-functional teams, ensuring that ATl's high-performance equipment meets production, safety, and regulatory standards.

Key Responsibilities:

Asset Integrity Program Development:

• Develop and manage a comprehensive Asset Integrity Management System (AIMS) tailored to ATl's advanced manufacturing environment.
• Set standards and guidelines for maintaining the structural and operational integrity of key assets, aligning with ATl's high-performance materials production goals.
• Implement strategies for asset optimization, ensuring maximum availability and minimizing operational disruptions.
• Utilize advanced analytical tools and methodologies to assess the reliability and performance of manufacturing equipment and processes. Develop a Process/Equipment reliability program and OEE metrics.

Program and Project Management:

• Develop Project Charters for maintenance-related capital funding requests.
• Conduct cost/benefit analysis for improvements to processes and/or equipment.
• Use expert judgment and ability to propose different solutions outside of set parameters, to address complicated manufacturing equipment issues. Collaborate with multiple external sources to arrive at World Class solutions.

Inspection and Monitoring:

• Lead the inspection and monitoring of assets using advanced technologies like non-destructive testing (NDT), ultrasound, and corrosion monitoring to assess and predict equipment performance.
• Perform failure analysis on process equipment to determine corrective actions to prevent failures and extend equipment life as well as work with project engineering during all phases of capital projects to ensure equipment reliability and maintenance considerations are incorporated.
• Oversee condition monitoring efforts to identify and address potential integrity
• issues before they impact production.
• Serve as the maintenance representative on select projects.

Risk Management and Failure Analysis:

• Conduct root cause analysis (RCA) and failure mode and effects analysis (FMEA) to understand failures and implement corrective actions to product quality and regulatory compliance.
• Perform risk-based inspections (RBI) and fitness-for-service (FFS) assessments to prioritize assets needing attention based on risk and criticality to operations.

Maintenance and Repair Strategy:

• Implement predictive maintenance programs leveraging data analytics, condition monitoring techniques, and sensor technologies.
• Collaborate with the maintenance team to develop preventive and corrective maintenance schedules focused on extending asset life, reducing downtime, and ensuring equipment is aligned with ATI's production goals.
• Manage shutdowns, overhauls, and repairs for critical production assets used in the specialty alloys manufacturing process.

Regulatory Compliance:

• Ensure all asset integrity activities comply with industry standards such as ASME, API, and internal safety regulations.
• Stay updated on industry standards and best practices in materials manufacturing and ensure that ATI's integrity management programs are up-to-date with evolving regulations.

Data Management and Reporting:

• Maintain accurate records of reliability assessments, maintenance activities, and equipment performance metrics. Prepare reports and presentations summarizing key findings, recommendations, and performance trends for management review.
• Report on key performance indicators (KPls) such as mean time between failures (MTBF), mean time to repair (MTTR), and other metrics related to asset health and performance.
• Drive cataloging and criticality classification of plant assets.

Technology Implementation:

• Lead the implementation of emerging technologies such as digital twins and IoT based predictive maintenance systems to improve ATI's asset management strategies.
• Explore innovative ways to improve asset reliability using predictive analytics, automation, and other cutting-edge technologies in the materials industry.

Team Leadership and Development:

• Lead a cross-functional team of integrity engineers, inspectors, and maintenance personnel, fostering a culture of continuous improvement.
• Provide training on asset integrity best practices and ensure the team is knowledgeable about the latest tools and techniques in performance materials and components manufacturing.
• Provide training to operators, technicians, and maintenance staff on techniques for managing equipment to improve reliability and uptime.

Collaboration with Operations and Engineering:

• Assist production Engineers in the design, build, and procurement of equipment, as it pertains to spare parts, preventative maintenance, predictive maintenance, repairs and rebuild of equipment, machine health strategy, and continuous improvement.
• Experience with fitness-for-service (FFS) and risk-based inspection (RBI) methodologies.
• Familiarity with pressure vessel codes (ASME, API) and pipeline integrity standards.
• Perform all other duties and special projects as assigned.

Key Experience & Capabilities:

• Bachelor's degree in engineering from an accredited university and/or 8 years of relevant manufacturing experience.
• Certified Maintenance Reliability Professional (CMRP) certification is preferred.
• 8+ years of relevant reliability and maintenance experience required, with experience in Aerospace and Defense, Metals, or Oil & Gas type manufacturing industries preferred.
• Proven experience in leading and managing cross-functional teams in asset integrity or maintenance activities, with experience in establishing a maintenance program.
• Strong understanding of reliability engineering principles, including failure analysis, root cause analysis, and reliability modeling techniques.
• Familiarity with manufacturing processes, equipment, and regulatory requirements.
• Excellent communication and collaboration skills, with the ability to work effectively in cross-functional teams and influence stakeholders at all levels of the organization.
• Ability to analyze complex asset performance data, identify potential risks, and make data-driven recommendations for improvement.
• High level of proficiency in developing and implementing the strategies required to realize growth goals and objectives; effectively communicating strategies and priorities in a manner that is clear and compelling; identifying and eliminating barriers to implementation.
• Visibly demonstrating a sense of urgency and strong personal ownership to business performance.
• ATI has ~30 manufacturing sites located in various regions around the country; therefore, we require candidates who are willing and able to travel as needed for project assignments and engagements. The ability to adapt to different locations, cultures, and work environments is essential, as it allows our team members to collaborate effectively with clients and colleagues nationally.

Desired Certifications:

• API 510, 570, 653 (certifications related to pressure vessel, piping, and storage tank inspection)
• Certified Reliability leader (CRL)
• Certified Maintenance and Reliability Professional (CMRP)
• NACE Certified Corrosion Specialist

*It is ATI's policy to not provide immigration sponsorship for any of the company's positions.

ATI and its subsidiary companies will provide equal employment opportunities to all applicants without regard to applicant's race, color, religion, sex, sexual orientation, gender identity, genetic information, national origin, age, veteran status, disability status, or any other status protected be federal or state law. The company will provide reasonable accommodations to allow an applicant to participate in the hiring process if so requested.