Process Engineer IV

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.

Job Summary
The Senior Process Engineer 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 a 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

• 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 (mat 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 QA laboratory. Responsible for the product quality, routine testing and interpretation of results, maintain records, ensure product compliance to specifications, maintain UL/ICC-ES certification, elaborate evaluation for segregated materials, and perform reports and metrics. Lead the application and interpretation of SPC charting. Conduct internal compliance audits of production tests, process specifications, plant change notices (PCN’s), and other in-plant processes. Lead jobsite inspections and claim analysis at plant level.
  
  Perform root cause analysis for reported issues from the field. Maintain communication with main lab at Parsippany to track claims, elaborate reports, and lead improvement projects associated with customer claims.

• 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.

• Lead the Confined Space and Hazardous Work Programs. Gatekeeper for EHS audits, lead meetings, train personnel, update documentation, ensure compliance, and evaluate records.

Qualifications Required

• Bachelor’s Degree in Arts/Sciences (BA/BS) in Engineering Required

• 5+ years of experience in an industrial continuous process atmosphere

General Knowledge,

Skills and Abilities

• Advanced demonstrated communication skills

• Advanced analytical skills

• Intermediate organizational skills and attention to detail

• Advanced problem solving skills

• Ability to multi task

• Knowledge of training delivery

Technical Knowledge,

Skills and Abilities

• 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…