Reliability Engineer III

About the Role

GAF is constructing a new shingle manufacturing facility in Newton, KS, and hiring is underway for the initial plant leadership team. This greenfield startup offers the opportunity to travel to other locations, engage with peers, support hiring, and participate in facility design and construction. The first years will be rewarding and challenging, with a supportive team. You will wear many hats during construction and commissioning, easing into your steady role over time.

Newton, Kansas, is a vibrant community with a population of about 20,000, featuring an active arts scene, historic districts, museums, trails, restaurants, shops, and first-class amenities. Located near Wichita, it offers a collaborative environment and a high quality of life.

Responsibilities

• Promote a safe and clean work environment, prioritizing safety as the highest cultural value.
• Guide technicians in gathering predictive data, ensuring proper techniques through training and established procedures.
• Initiate work orders for equipment showing signs of failure and follow up on their completion.
• Optimize existing predictive maintenance routes and expand programs as needed.
• Develop engineering solutions to address problems identified during root cause analyses.
• Prepare capital requests for various projects.
• Collaborate with planners and schedulers to effectively delegate internal labor resources.
• Prepare project scopes and review them with contractors for external labor needs.
• Ensure timely project completion while adhering to budget constraints.
• Review preventive maintenance (PM) schedules and plans to ensure appropriate frequency and scope.
• Conduct Failure Modes and Effects Analysis (FMEA) on machinery.
• Perform comprehensive asset analyses, including utilization, Overall Equipment Effectiveness (OEE), remaining useful life, and other relevant parameters to assess condition, reliability, and costs.
• Establish preventive maintenance requirements and service contracts, identify critical spares, and evaluate new equipment and techniques to ensure equipment reliability.
• Monitor and confirm equipment reliability through regular audits and performance tracking using Key Performance Indicators (KPIs).
• Utilize Pareto analysis to identify key equipment failures and maintenance spending areas of greatest concern.
• Track maintenance department KPIs to assess departmental effectiveness.
• Monitor equipment failures, analyze costs using Pareto principles, and identify root causes of equipment failures.
• Formulate teams to address equipment failures and develop action items to prevent recurrence.
• Track action items and drive them to completion to reduce maintenance costs.
• Oversee MRO storeroom functions and integrate reliability elements into storeroom processes.
• Champion Operator Care initiatives (TPM) and influence internal and external stakeholders through strong communication, problem-solving, and cross-functional leadership.
• Perform other job duties as assigned.

Requirements

• Bachelor’s Degree in Engineering.
• 5+ years of demonstrated industrial manufacturing experience, preferably in a continuous manufacturing process.
• 5+ years of plant maintenance experience.
• 5+ years of experience in maintenance and reliability improvement.
• Willingness and aptitude to pursue Level 1 certifications in Thermography, Vibration Analysis, and Machinery Lubrication within the first two years (prior certifications may satisfy this requirement).

Skills

General Knowledge, Skills, and Abilities

• Excellent interpersonal skills.
• Strong attention to detail with a commitment to quality and accuracy.
• Ability to handle multiple projects simultaneously.
• Ability to work effectively in a team environment.
• Able to influence and lead others over whom he/she has no direct authority.
• Willing to drive change in the interest of continuous improvement.
• Excellent verbal and written communication skills.
• Able to work under limited supervision, make independent judgments, and decisions as necessary.
• Excellent organization skills.

Technical Knowledge, Skills, and Abilities

• Advanced knowledge of CMMS/Inventory Management software.
• Intermediate proficiency in G Suite.
• Expertise in applying advanced probability and statistical modeling and prediction reliability tools to forecast equipment life, assess system reliability, and make data-driven decisions.
• Expertise in complex equipment types and their failure mechanisms across diverse industrial systems, including advanced rotating machinery, complex hydraulic and pneumatic systems, advanced bearing analysis, and sophisticated lubrication management programs.
• Advanced proficiency using root cause analysis to troubleshoot and solve problems.
• Extensive experience and strategic application of all major Predictive Maintenance (PdM) tools and techniques, including advanced interpretation and program management for Vibration Analysis, Infrared Thermography, Ultrasonic Testing, Oil Analysis, Motor Current Signature Analysis (MCSA), and Non-Destructive Testing (NDT).
• Deep expertise in Reliability-Centered Maintenance (RCM) analysis processes, including leading comprehensive asset criticality assessments, facilitating complex Failure Modes, Effects, and Criticality Analysis (FMECA) studies, and driving PM/PdM optimization strategies.
• Command of precision maintenance technologies and practices, including advanced laser alignment, dynamic balancing, machine shop practices, and development of engineering specifications for maintaining machinery to world-class tolerances.
• Exceptional problem-solving and analytical skills, capable of diagnosing highly complex technical and systemic issues, developing innovative solutions, and evaluating their long-term effectiveness and return on investment.
• Ability to interpret and apply complex engineering specifications, P&IDs, blueprints, schematics, and industry codes, translating them into actionable maintenance and reliability strategies.
• Comprehensive understanding of end-to-end operational processes, with strategic insight to identify how maintenance and reliability activities impact production efficiency, product quality, and overall business objectives.
• Deep familiarity and practical application of standard manufacturing concepts, practices, and procedures, including Lean Manufacturing, Six Sigma, Total Productive Maintenance (TPM), and other continuous improvement methodologies.
• Proven ability to develop and deliver technical training programs to maintenance technicians, operators, and engineers on reliability concepts and best practices.
• Advanced knowledge of operational processes and how maintenance activities can impact them.
• Advanced knowledge of standard manufacturing concepts, practices, and procedures.

Preferred Qualifications

• SMRP or Certified Maintenance Reliability Professional certification.
• Six Sigma Green or Black Belt.
• Intermediate proficiency in Microsoft Office and/or Google Suite.
• Advanced knowledge of rotating equipment, hydraulics, pneumatics, bearings, and lubrication.
• Advanced knowledge of vibration analysis, thermal imaging, oil analysis, non-destructive testing, and laser alignment.
• Expert knowledge of reliability-centered maintenance analysis processes.
• Ability to read and interpret technical documents, including blueprints, schematics, P&IDs, and equipment manuals.
• Experience working with CMMS management software.
• Advanced knowledge of probability and statistical modeling and prediction reliability tools.
• Demonstrated ability to develop, prioritize, and execute plans to deliver results on multiple projects.
• Small capital project management skills.

Physical Demands

• Stationary Position: Occasionally
• Move/Traverse: Frequently
• Stationary Position/Seated: Occasionally
• Transport/Lifting: Frequently
• Transport/Carrying: Frequently
• Exerting Force/Pushing: Frequently
• Exerting Force/Pulling: Frequently
• Ascend/Descend: Frequently
• Balancing: Occasionally
• 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: Occasionally
• 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
• Vibration: Frequently

Pay

Base Salary Range: $92,000–$126,500. Individual compensation offers will be determined based on geographic location, relevant experience, skills, education, and qualifications.

Travel Requirements: 10%

Benefits

• A wide range of health insurance options, including medical, dental, and vision for you and your family.
• Family-building benefits supporting fertility and parenthood journeys.
• Robust 401K plan with employer match contributions for pre-tax and/or Roth contributions.
• Wellness program, free financial coaching, referral program, and product rebates for your primary residence.
• Professional growth and development through internal training programs, courses, and a generous tuition reimbursement program.
• Opportunities to connect, empower, evolve, and inspire through a culture reflecting company values.