Senior Process Engineer IV

Introduction

At GAF, we cover more than just buildings. We cover each other. Under this roof, you will have the tools and resources you need to grow and develop in your career. You will experience our incredible culture and will be empowered to support your teammates, your customers, and especially your community. Under this roof, we define the future while leading the present through our deep well of experience and our responsibility to the future to drive improvements and innovation in our products. We are GAF. And under this roof, we protect what matters most.

Summary

The Senior Process Engineer IV is responsible for engineering needs, demonstrating skills in plant troubleshooting, process design, continuous improvements and quality management. The incumbent’s primary focus is to maintain control over the product quality in combination with proper process control and manufacturing stability. This incumbent is directly involved with new product development, improvement evaluations and monitoring of key process indicators.

Essential Duties

Specific responsibilities include, but are not limited to:

• Lead the execution of quality and process improvement projects and activities, using standard PI tools such as Qualpro, MVT/DOE, Kepner Tregoe PSDM, Six-sigma, etc., use the Hierarchy of Values (Safety, Quality, Service, Cost) to prioritize. Activities include variation reduction, increased productivity, reduced scrap, and increased efficiency in the different plant processes (shingle manufacturing, asphalt oxidation, shipping goods, etc.). Lead centerlining efforts within plant personnel. Maintain centerlining documentation, plan and lead meetings with team members, elaborate reports, quantify the improvements, and train personnel.

• Lead the process design review, raw material qualification, product and process qualification, and capability studies. Perform PPA/FMEA on all major process and raw material changes. Coordinate Plant trials with R&D and plant personnel. Ensure trials are accurately conducted and reported on a timely manner.

• Responsible for ensuring implementing major production/maintenance processes changes and projects. Take into consideration cost, structure, safety, maintainability, facility of production, and the availability of materials and equipment. Participate on problem solving teams and project teams as a technical resource geared towards improving the performance of existing processes and raw material handling systems. Assist in the implementation of the capital projects to renew, replace, improve or introduce new manufacturing equipment.

• Will supervise up to 4 Quality Lab Technicians across multiple shifts

Physical Demands

• Ability to read and concentrate via computer data entry typing and proofreading

• Must be able to climb ladders and/or stairs and walk on open grating on elevated surfaces

• Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions

• Required to reach with hands and arms and stoop, kneel, or crouch

• Frequent sitting, walking, and standing, and occasional climbing, stooping, kneeling, crouching, crawling, and balancing

• Frequent use of eye, hand, and finger coordination enabling the use of office machinery

• Oral and auditory capacity enabling interpersonal communication as well as communication through automated devices such as the telephone

• Required to sit, stand, walk and use hands to finger, handle or feel objects, tools, or controls

• Specific vision abilities required by the job include close vision, peripheral vision, depth perception, and the ability to adjust focus

• Must continuously have the ability to differentiate colors precisely

• Occasionally lift and/or move up to 10 pounds and occasionally up to 50 pounds

Under This Roof, We Require

• Bachelor degree in Engineering

• 7+ years of experience in complex manufacturing environment (industrial continuous process atmosphere preferred)

• 2+ years people management experience required

• Advanced ability to read and interpret specifications and drawings

• Advanced proficiency using root cause analysis to troubleshoot and solve problems

• Advanced ability to translate technical data into a format and language suitable for personnel

• Advanced skills in process hazard analysis and process safety management

• Advanced proficiency in Minitab, WinSPC, and AutoCAD (preferred)

• Advanced knowledge of manufacturing analysis tools, such as statistical analysis/statistical process control (SPC), process capability studies, lean manufacturing, 5S, Six Sigma, Kepner Tregoe (preferred), and/or Design of Experiments (DOE)

• Strong knowledge of engineering fundamentals

• Strongly familiar with standard manufacturing concepts, practices & procedures

• Advanced demonstrated communication skills

• Advanced analytical skills

• Intermediate organizational skills and attention to detail

• Advanced problem solving skills

• Ability to multitask

• Knowledge of training delivery

Under This Roof, We Also Value

• Adaptability

• Building Strategic Working Relationships

• Technical/Professional Knowledge & Skills

• Stress Tolerance

• Decision Making

• Communication

How We Protect What Matters Most

• We offer a wide range of health insurance options that include medical, dental, and vision for you and your family.

• Our Family-Building benefits support the many different journeys to fertility and parenthood.

• Our robust 401K plan includes an employer match contribution with your pre-tax and/or Roth contributions.

• Other exciting programs and perks are available to help employees achieve work-life balance, including (but not limited to) a wellness program, free financial coaching, a referral program, and product rebates when purchased for an employee’s primary residence.

• Professional growth and development are very important to us! We offer internal training programs and courses, as well as a generous tuition reimbursement program.