Reliability Engineer III

GAF•Newton, KS

3d•$104,000 - $143,000•Onsite

About The Position

The Reliability Engineer III is an expert-level role responsible for strategic leadership of the site’s Reliability program and its continuous improvement across operations. As a peer to Maintenance and Production Managers, the position applies advanced engineering expertise to prevent equipment failures, optimize maintenance, and lead complex projects with site-wide impact. The role also oversees MRO storeroom functions, incorporates reliability practices into storeroom processes, and champions Operator Care initiatives (TPM), influencing stakeholders through communication, problem-solving, and cross-functional leadership. The position supports the startup of GAF’s new shingle manufacturing facility in Newton, Kansas. During construction and commissioning, the employee may take on varied responsibilities, travel to other locations, support hiring, and participate in facility design and construction before transitioning into the steady-state role. Startup and commissioning may initially require up to 50% travel; the posting also lists a 10% travel requirement and notes occasional travel for conferences, site visits, professional development, or learning opportunities. The role is based at the Newton facility. The listed base salary range is $104,000–$143,000, and a $10,000 sign-on bonus is offered. The position involves frequent movement, lifting and carrying, pushing and pulling, climbing, stooping, kneeling, crouching, and crawling, with constant reaching and handling. Working conditions frequently include extreme cold and heat, humidity, wetness, noise, hazards, and temperature changes.

Requirements

Bachelor’s degree in Engineering.
At least 5 years of demonstrated industrial manufacturing experience, preferably in a continuous manufacturing process.
At least 5 years of plant maintenance experience.
At least 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, as business priorities allow; prior certifications may satisfy this expectation.
Excellent interpersonal, verbal communication, and written communication skills.
Strong attention to detail and commitment to quality and accuracy.
Ability to manage multiple projects simultaneously and work effectively in a team environment.
Ability to influence and lead people without direct authority and drive continuous improvement and change.
Ability to work under limited supervision and make independent judgments and decisions.
Excellent organizational skills.
Advanced knowledge of CMMS and inventory management software.
Intermediate proficiency in G Suite.
Expertise in probability and statistical modeling and predictive reliability tools for forecasting equipment life and assessing system reliability.
Expertise in complex equipment and failure mechanisms, including rotating machinery, hydraulic and pneumatic systems, bearing analysis, and lubrication programs.
Advanced proficiency in root cause analysis and troubleshooting.
Extensive experience applying and interpreting predictive maintenance tools, including vibration analysis, infrared thermography, ultrasonic testing, oil analysis, motor current signature analysis, and non-destructive testing.
Deep expertise in Reliability-Centered Maintenance (RCM), asset criticality assessments, FMECA, and PM/PdM optimization.
Command of precision maintenance practices, including laser alignment, dynamic balancing, machine shop practices, and machinery engineering specifications.
Exceptional problem-solving and analytical skills, including evaluating solutions and long-term effectiveness and return on investment.
Ability to interpret and apply engineering specifications, P&IDs, blueprints, schematics, and industry codes.
Comprehensive understanding of how maintenance and reliability affect production efficiency, product quality, and business objectives.
Practical knowledge of Lean Manufacturing, Six Sigma, TPM, and other continuous improvement methodologies.
Ability to develop and deliver technical training to maintenance technicians, operators, and engineers.
Advanced knowledge of operational processes and the effects of maintenance activities on them.
Advanced knowledge of standard manufacturing concepts, practices, and procedures.

Nice To Haves

SMRP or Certified Maintenance Reliability Professional certification.
Six Sigma Green Belt 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 blueprints, schematics, P&IDs, equipment manuals, and other technical documents.
Experience with CMMS management software.
Advanced knowledge of probability and statistical modeling and predictive reliability tools.
Demonstrated ability to develop, prioritize, and execute plans across multiple projects.
Small capital project management skills.

Responsibilities

Promote a safe and clean work environment, embedding safety as the highest priority.
Guide technicians in gathering predictive data and ensure correct 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 for problems identified through root cause analyses.
Prepare capital requests for projects.
Collaborate with planners and schedulers to delegate internal labor resources effectively.
Prepare project scopes and review them with contractors for external labor needs.
Ensure projects are completed on time and within budget.
Review preventive maintenance schedules and plans to ensure appropriate frequency and scope.
Conduct Failure Modes and Effects Analysis (FMEA) on machinery.
Analyze assets, including utilization, Overall Equipment Effectiveness (OEE), remaining useful life, condition, reliability, and costs.
Establish preventive maintenance requirements and service contracts, identify critical spares, and evaluate equipment and techniques for reliability.
Monitor equipment reliability through audits and performance tracking using Key Performance Indicators (KPIs).
Use Pareto analysis to identify significant equipment failures and maintenance spending areas.
Track maintenance department KPIs to assess effectiveness.
Monitor equipment failures, analyze costs, and identify root causes.
Form teams to address equipment failures and develop actions to prevent recurrence.
Track action items through completion to reduce maintenance costs.
Oversee MRO storeroom functions and integrate reliability elements into storeroom processes.
Champion Operator Care initiatives (TPM) and lead continuous improvement of the site Reliability program.
Perform other job duties as assigned.