Maintenance Process Engineer

Job Title: Maintenance Process Engineer

Department: Maintenance

Plant Location: Fairland, IN.

Position Summary:

The Maintenance Process Engineer ensures the reliability, efficiency, and maintainability of high-speed coil coating equipment, including uncoilers, recoilers, ovens, tension levelers, and chemical treatment systems. This role applies predictive maintenance strategies, process control optimization, and automation troubleshooting to maximize uptime and minimize costs.

Key Responsibilities:

Equipment Reliability & Predictive Maintenance:

- Develop and implement Reliability-Centered Maintenance (RCM) strategies for uncoilers, recoilers, bridle rolls, tension levelers, and curing ovens.

- Utilize vibration analysis, infrared thermography, ultrasonic leak detection, and oil analysis to prevent failures.

- Improve Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR) through data-driven insights.

- Design and refine CMMS-driven preventive maintenance schedules for mechanical, and electrical.

- Standardize maintenance procedures, ensuring optimal lubrication practices, alignment techniques, and torque settings.

Automation & Process Control Optimization:

- Troubleshoot and improve PLC (Programmable Logic Controller) and SCADA (Supervisory Control and Data Acquisition) systems used for real-time monitoring and control.

- Optimize control loops for chemical coating applications, oven curing temperature profiles, and tension control systems.

- Develop and refine HMI (Human-Machine Interface) logic to enhance operator efficiency and fault diagnosis.

Process Engineering & Performance Optimization:

- Analyze OEE (Overall Equipment Effectiveness) to identify bottlenecks processes and improve uptime.

- Optimize chemical coating system reliability, including pH, viscosity, and film thickness control.

- Develop energy efficiency projects for compressed air, cooling, and heat recovery systems.

Electrical & Mechanical Systems Management:

- Maintain 480V 3-phase power distribution, arc flash compliance (NFPA 70E), and servo-controlled actuators.

- Manage hydraulic/pneumatic systems, ensuring proper pressure regulation and leak detection.

- Oversee alignment, calibration, and maintenance of servo motors, encoders, and linear actuators used in precision coil processing.

Continuous Improvement & Lean Six Sigma Integration:

- Lead Kaizen events, Six Sigma projects, and Total Productive Maintenance (TPM) initiatives.

- Implement 5S principles, Standard Work Instructions (SWIs), and Job Hazard Analyses (JHAs).

Regulatory Compliance & Safety:

- Ensure compliance with OSHA, EPA, NFPA, and ISO 9001/14001 standards.

- Develop and enforce Lockout/Tagout (LOTO), confined space, and hot work safety procedures.

Working Conditions:

- Operates in a manufacturing and heavy industrial environment, with exposure to moving machinery, high temperatures, airborne particulates, and chemical coatings.

- Works in both office and production areas, requiring frequent hands-on troubleshooting.

- Requires flexibility to respond to emergency breakdowns and be on-call for critical failures.

- Uses personal protective equipment (PPE) such as steel-toe boots, and hearing protection.

Qualifications: Education/Experience:

- Bachelor’s degree in mechanical engineering, Electrical Engineering, Industrial Maintenance, or a related field preferred. Equivalent experience with industry certifications may be considered.

- 5+ years in industrial maintenance, reliability, or process engineering, preferably in coil coating, roll-to-roll processing, or metals manufacturing.

- Experience with CMMS, predictive maintenance, and industrial automation.

- Preferred: CMRP, Six Sigma Green/Black Belt, or CIMM certification.

Behavioral Competencies:

- Analytical mindset: Data-driven approach to troubleshooting and process optimization.

- Collaboration: Works cross-functionally with maintenance, production, and engineers.

- Continuous improvement: Strong focus on efficiency, cost reduction, and reliability.

- Attention to Detail: Ensures precision in process control, equipment calibration, and failure analysis.

Physical Requirements:

- Ability to lift up to 75 lbs. and work in confined spaces, high elevations, and extreme temperatures.

- Exposure to high temperatures, coatings, solvents, and rotating machinery.

- On-call availability for emergency maintenance.

- Ability to detect abnormal machine noises, alarms, and troubleshooting signals.

This job description is intended to outline the general nature and level of work being performed by employees in this role. It is not an exhaustive list of all responsibilities, duties, and skills required. Management reserves the right to modify, add, or remove duties as necessary.

By choice, Jupiter Aluminum is committed to creating a diverse workforce. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status, or veteran status.

Job Type: Full-time

Benefits:

- 401(k)

- 401(k) matching

- Dental insurance

- Employee assistance program

- Employee discount

- Flexible schedule

- Flexible spending account

- Health insurance

- Health savings account

- Life insurance

- Paid time off

- Referral program

- Tuition reimbursement

- Vision insurance

Work Location: In person