About this opportunity
HYCAST LLC lists this Maintenance Reliability Engineer opportunity in fairfield, Iowa. Review the employer’s description below for duties, qualifications and application requirements.
Job description
Job Description Job Description Job Title
Maintenance Reliability Engineer - Foundry Operations
Reports To
Maintenance Manager
Position Summary
The Maintenance Reliability Engineer is responsible for improving equipment reliability, uptime, and maintainability across all foundry operations. This role bridges maintenance, engineering, and operations to eliminate unplanned downtime, extend asset life, and support safe, cost-effective production. The position focuses on root cause failure analysis, preventive and predictive maintenance optimization, reliability-centered maintenance (RCM), and continuous improvement of foundry equipment and systems.
Key Responsibilities
Reliability & Asset Performance
Develop and execute reliability strategies for critical foundry assets including melting furnaces, molding lines, core machines, shakeout, sand systems, conveyors, and material handling equipment
Lead Root Cause Failure Analysis (RCFA) and implement permanent corrective actions
Track, analyze, and report reliability KPIs such as MTBF, MTTR, equipment availability, and downtime trends
Identify chronic equipment issues and drive long-term solutions
Maintenance Strategy & Planning
Design, optimize, and maintain Preventive Maintenance (PM) and Predictive Maintenance (PdM) programs
Support condition monitoring efforts (vibration, thermography, oil analysis, ultrasound, etc.)
Improve job plans, task frequencies, and maintenance standards based on failure data
Partner with maintenance planners and supervisors to improve schedule compliance and wrench time
Engineering & Continuous Improvement
Support capital projects, equipment upgrades, and new equipment installations with a focus on reliability and maintainability
Perform Failure Modes and Effects Analysis (FMEA) on existing and new assets
Standardize parts, tools, and maintenance procedures to reduce complexity and cost
Drive continuous improvement initiatives using Lean, TPM, or Six Sigma methodologies
Safety, Compliance & Documentation
Ensure all reliability and maintenance activities comply with safety, environmental, and regulatory requirements
Support MOC (Management of Change) processes related to equipment modifications
Maintain accurate asset records, BOMs, and maintenance documentation within the CMMS
Cross-Functional Collaboration
Work closely with operations, maintenance, engineering, and purchasing teams to align reliability goals
Provide technical guidance and training to maintenance technicians
Support outage planning and major maintenance events
Required Qualifications
Bachelor's degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, or related field is preferred
5-10 years of experience in maintenance, reliability, or engineering within a foundry or heavy industrial environment
Strong understanding of rotating equipment, hydraulics, pneumatics, and industrial power systems
Experience with CMMS systems and reliability data analysis
Proven ability to lead RCFA and drive corrective actions
Preferred Qualifications
Foundry-specific experience (iron, steel, aluminum, or other metal casting)
Certification or training in Reliability Engineering, RCM, TPM, or Six Sigma
Experience with furnace systems, sand handling, dust collection, and high-temperature processes
Familiarity with OSHA, NFPA, and environmental compliance in industrial settings
Key Competencies
Analytical and problem-solving mindset
Strong communication and cross-functional leadership skills
Hands-on technical aptitude
Data-driven decision making
Continuous improvement orientation
Physical & Work Environment
Manufacturing/foundry environment with exposure to heat, dust, noise, and industrial equipment
Ability to walk plant floor, climb ladders, and respond to equipment issues as needed
Occasional off-shift or weekend support during outages or critical failures
Company Description HyCast Foundry is a premier U.S. foundry specializing in the production of high-quality gray and ductile iron castings. Committed to safety, sustainability, and operational excellence, HyCast aims to drive innovation in the metal casting industry while fostering a collaborative and dynamic workplace culture.
Company Description HyCast Foundry is a premier U.S. foundry specializing in the production of high-quality gray and ductile iron castings. Committed to safety, sustainability, and operational excellence, HyCast aims to drive innovation in the metal casting industry while fostering a collaborative and dynamic workplace culture.
Worksite address
fairfield, IA, 52556, US
Who can apply
Review the original listing for work authorization, qualifications and employer requirements.