Production Operator IV

About the Role

GAF is constructing a new shingle manufacturing facility in Newton, KS, and is hiring for the initial plant leadership team. As an Operator IV, you will serve as a Master Technician, responsible for optimizing plant-wide production systems, defining best practices, and ensuring operational excellence. This role involves diagnosing and resolving complex, systemic process issues, owning high-impact continuous improvement projects, and directly training and certifying all levels of Production Operators.

During the construction and commissioning phases, you will wear many hats, with opportunities to travel to other GAF locations, engage with peers, support hiring, and participate in facility design and construction.

Essential Duties

• Lead and audit complex setups and changeovers across multiple production lines, including line clearances and equipment adjustments, ensuring proper documentation.
• Define and implement optimal machine parameters across all production lines to maximize flow, efficiency, and quality standards plant-wide.
• Serve as the plant-level technical expert for diagnosing and resolving complex, systemic process issues and major equipment failures using advanced root-cause analysis tools.
• Develop, implement, and audit preventive maintenance (PM) programs and work orders in collaboration with maintenance and engineering teams.
• Design and manage high-level defect containment strategies and corrective actions, ensuring site-wide compliance with quality assurance protocols.
• Audit and maintain production data integrity at a macro level, including accurate tracking of scrap, downtime codes, and throughput metrics, and report findings to management.
• Lead the planning and execution of trials for new products and processes, and be responsible for the creation and publication of all associated Standard Operating Procedures (SOPs).
• Lead and implement major continuous improvement initiatives, including Kaizen events and 5S audits, driving cultural change and measurable improvements.
• Own and direct plant safety activities, such as near-miss reporting, Job Safety Analyses (JSAs), and safety audits, ensuring all personnel adhere to policies.
• Act as the primary trainer and certifier for Level 1, Level 2, and Level 3 operators, including developing advanced training materials.
• Ensure effective shift handoffs with clear documentation and communication, mentoring shift leads on best practices.
• Regularly act as shift lead, backfill, or Area Supervisor, coordinating team activities and ensuring smooth operations across a defined zone.
• Collaborate with cross-functional teams (Engineering, R&D, Management) to define and drive reliability improvements and achieve long-term production goals.
• Partner with other key stakeholders to ensure successful implementation of Process/project engineering, Maintenance and other process improvement projects, and become the practical expert to train and lead the change with the frontline team.
• Perform other duties as assigned.

Qualifications

Required

• H.S. Diploma or General Education Degree (GED)
• 5+ years of experience in a safety-sensitive industrial or manufacturing environment.
• Demonstrated mastery of all critical production systems, setups, and changeovers across multiple lines.
• Proven history of leading continuous improvement projects and implementing safety/quality initiatives.

General Knowledge, Skills, and Abilities

• A demonstrated commitment to safety
• Excellent interpersonal skills
• Strong attention to detail
• Ability to work as a team player
• Identifies and reports issues to supervisors and seeks proactive resolution
• Strong communication skills
• Adaptability to changes in production schedules or processes to maintain workflow
• A relentless pursuit for learning and improving processes within the production role
• Ability to follow instructions and make basic decisions within the scope of the role
• Ability to identify problems and resolve conflicts within a collaborative, team-driven environment
• Excellent organization skills

Technical Knowledge, Skills, and Abilities

• Expert proficiency in G suite and various operating platforms and production applications.
• Adherence to health and safety policies, including the use of personal protective equipment.
• Understanding product safety regulations and handling instructions for hazardous substances.
• Expert understanding of the operation and maintenance of production machinery and associated processes.
• Familiarity with machine settings and making adjustments as needed to ensure smooth operation.
• Expert ability to identify and resolve issues and adjust settings to maintain production quality across interconnected systems.
• Awareness of production logistics, including handling and testing of pallets and materials.
• Expert familiarity with quality assurance protocols, such as knowledge of trial procedures, collecting samples for testing and verifying production targets.

Preferred

• 5+ years experience in high-volume manufacturing, distribution or logistics.
• Certification or advanced training in continuous improvement initiatives and Lean Manufacturing Methodologies (e.g., TPS, Kaizen, Six Sigma (green/black belt), 5S).
• Expert proficiency in root-cause analysis tools and techniques (e.g., 5 Whys, Fishbone).
• Multi-line production experience and documented success in optimizing parameters plant-wide.
• Advanced leadership, mentoring, and organizational skills.

Pay

Base Hourly Rate: $32.00

Benefits

• Wide range of health insurance options including medical, dental, and vision for you and your family.
• Family-Building benefits supporting the many different journeys to fertility and parenthood.
• Robust 401K plan with an employer match contribution for pre-tax and/or Roth contributions.
• Wellness program, free financial coaching, referral program, and product rebates when purchased for an employee's primary residence.
• Internal training programs and courses, as well as a generous tuition reimbursement program.
• Employee Resource Groups focused on education and allyship.

Physical Demands

• Stationary Position - Frequently
• Move/Traverse - Frequently
• Stationary Position/Seated - Frequently
• Transport/Lifting - Frequently
• Transport/Carrying - Frequently
• Exerting Force/Pushing - Frequently
• Exerting Force/Pulling - Frequently
• Ascend/Descend - Frequently
• Balancing - Frequently
• Position Self/Stooping - Frequently
• Position Self/Kneeling - Frequently
• Position Self/Crouching - Frequently
• Position Self/Crawling - Frequently
• Reaching - Constantly
• Handling - Constantly
• Grasping - Frequently
• Feeling - Occasionally
• Communicate/Talking - Frequently
• Communicate/Hearing - Frequently
• Repetitive Motions - Frequently
• Coordination - Frequently

Working Conditions

• Extreme cold - Frequently
• Extreme heat - Frequently
• Humid - Frequently
• Wet - Frequently
• Noise - Frequently
• Hazards - Frequently
• Temperature Change - Frequently
• Atmospheric Conditions - (not specified)
• Vibration - Frequently

Travel

May require occasional travel in connection to job duties as it relates to conferences, site visits, professional development or learning opportunities, etc., in which advance notice of travel expectations/events will be provided.