Maintenance Reliability Consultant Jobs in Texas

Reliability Consultants to provide deep asset reliability expertise to clients across the chemicals industry. The role focuses on improving equipment reliability, asset availability, mechanical integrity, and plant stability across batch, continuous, and specialty chemical operations. Consultants will assess existing reliability practices, identify performance, and risk gaps, and implement best-in-class reliability strategies, standard work, and digital / AI-enabled tools to deliver sustainable improvements in asset integrity, cost, unplanned downtime reduction, and overall manufacturing performance.

Key Responsibilities

Reliability Excellence Assessment & Roadmap Definition

• Independently assess asset reliability, and mechanical integrity practices across batch, continuous, and specialty chemical operations.

• Benchmark site performance against industry best practices and peer operations to identify gaps and improvement opportunities.

• Develop fact-based reliability excellence roadmaps, prioritizing initiatives based on risk, value, and ease of implementation.

• Provide objective, data-driven insights to client leadership on reliability risks, cost drivers, and asset performance.

Asset Performance & Reliability Improvement Implementation

• Lead or support implementation of reliability improvement initiatives, including asset criticality, failure mode management, and risk-based maintenance strategies.

• Identify and eliminate chronic equipment issues and systemic causes of unplanned downtime.

• Align operating discipline, maintenance practices, and execution routines to improve plant stability and asset life.

• Translate recommendations into practical, site-ready actions with clear ownership and timelines.

Mechanical Integrity, Safety & Risk Assurance

• Review and strengthen Mechanical Integrity and reliability-related PSM elements, including inspection regimes, MOC, PSSR, and asset risk management.

• Conduct field audits, maintenance walkdowns, and failure investigations to identify integrity and safety risks.

• Provide independent challenge and assurance that reliability improvements are implemented safely and in compliance with site and regulatory requirements.

• Support closure and sustainability of corrective and preventative actions.

Reliability Analytics, KPIs & Performance Control

• Assess reliability data quality and usage across CMMS/EAM, downtime systems, and condition monitoring tools.

• Define and implement reliability KPIs, dashboards, and governance routines to support sustained performance management.

• Quantify and track benefits from reliability initiatives, including reductions in downtime, maintenance cost, and operational risk.

• Provide transparent reporting to site and corporate leadership on progress and impact.

Maintenance Strategy, Turnarounds & Execution Excellence

• Review and optimize maintenance strategies, planning, and scheduling to improve execution effectiveness and wrench time.

• Support turnaround and shutdown assessments, readiness reviews, scope optimization, and post-event learning.

• Embed lessons learned into standard work and future maintenance strategies.

Digital Enablement & Capability Transfer

• Assess and deploy digital and AI-enabled reliability tools (CMMS/EAM optimization, predictive analytics, condition monitoring) to improve decision-making.

• Transfer knowledge through coaching, training, and development of standard work to ensure sustainability post-engagement.

• Build trusted client relationships through objective assessment, technical credibility, and hands-on implementation support.

Education:

• Education: Bachelor’s degree in chemical engineering or a closely related field. A master’s degree is a plus.

• Certifications: CMRP (Certified Maintenance & Reliability Professional) or CRL (Certified Reliability Leader) preferred.

Experience:

• Minimum 8+ years of experience in chemical manufacturing (petrochemical, specialty chem, or refining), with a strong emphasis on asset reliability, maintenance engineering, or reliability engineering roles within batch or continuous process environments.

• Hands-on experience working closely with operations and maintenance, including time spent in plant/area engineering, reliability engineering, maintenance leadership, or rotating equipment roles supporting day-to-day plant performance.

• Strong background in reliability fundamentals, including asset criticality analysis, failure modes and effects analysis (FMEA), RCFA, preventive and predictive maintenance strategies, and reliability data analysis.

• Direct involvement in turnarounds, shutdowns, and major maintenance events, including scope development, job planning, execution support, risk management, and post-event performance review.

• Demonstrated ability to drive reliability and asset performance improvements, such as reduced unplanned downtime, improved equipment availability, maintenance cost optimization, and increased mean time between failures (MTBF).

• Proven track record of delivering measurable improvements in reliability, safety, and cost through improved maintenance strategies, work management, spare parts optimization, and collaboration with operations.

• Familiarity with PSM requirements and mechanical integrity programs, including MOC, HAZOP/LOPA interfaces, inspection regimes, safe work practices, and disciplined asset lifecycle management in a regulated chemical environment.

Technical Skills:

• Strong knowledge of chemical plant reliability and maintenance practices, including asset criticality, mechanical integrity programs, preventive and predictive maintenance, work management, and reliability-centered maintenance (RCM).

• Working knowledge of core chemical processes (e.g., reaction, distillation, crystallization, polymerization, separation, drying, blending) with an understanding of how process conditions and operating discipline impact equipment health, failure modes, and asset life.

• Familiarity with PSM and Mechanical Integrity requirements, including PHA/HAZOP interfaces, MOC, PSSR, inspection and testing regimes, and safe work practices in regulated chemical environments.

• Experience with reliability-focused digital tools, such as CMMS/EAM systems (SAP, IBM Maximo, Infor/Hexion, etc), condition monitoring and predictive analytics, mobile maintenance execution, reliability dashboards, and visual management of asset performance.

Soft Skills:

• Exceptional analytical and problem-solving skills.

• Strong written and verbal communication skills, including the ability to present complex technical information to non-technical stakeholders.

• Ability to work independently and as part of a global, multi-disciplinary team.

• Willingness to travel extensively to client sites.