Reliability Engineer IIIAt 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. The Reliability Engineer III is an expert-level position, driving significant improvements in machine operating time, uptime, and overall equipment reliability. This position holds overall strategic leadership responsibility for the site's Reliability program, leading its development and continuous improvement across all operations functions. As a strategic leader and peer to Maintenance and Production Managers, the Reliability Engineer III applies advanced engineering expertise to prevent failures, optimize maintenance activities, and manage complex projects with site-wide impact. This dynamic role also oversees MRO storeroom functions, integrates reliability elements into storeroom processes, and champions Operator Care initiatives (TPM), influencing internal and external stakeholders through strong communication, problem-solving, and cross-functional leadership to achieve strategic change.
Essential Duties:- Promotes a safe and clean work environment where safety is the highest priority and embedded in our culture.
- 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 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 the root causes of equipment failures.
- Formulate teams to address equipment failures and develop action items to prevent recurrence.
- Track action items and drive to completion to reduce maintenance costs.
- Perform other job duties as assigned
- Qualifications Required
- Bachelor's Degree in Engineering 5+ years 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 & aptitude to pursue Level 1 certifications in Thermography, Vibration Analysis, and Machinery Lubrication within your first two years, as business priorities allow. (Note: Prior certifications obtained through GAF or another employer may fully satisfy this expectation).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 for change in the interest of continuous improvement.
Excellent verbal and written communication skills.
Able to work under limited supervision make independent judgement 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 but not limited to 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). You'll lead the selection, implementation, and optimization of these technologies.
Deep expertise in Reliability-Centered Maintenance (RCM) analysis processes, including leading comprehensive asset criticality assessments across entire facilities, facilitating complex Failure Modes, Effects, and Criticality Analysis (FMECA) studies, and driving PM/PdM optimization strategies for maximum asset availability and lowest life-cycle cost.
Command of precision maintenance technologies and practices, including advanced laser alignment, dynamic balancing, machine shop practices, and the 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 the strategic insight to identify how maintenance and reliability activities can profoundly 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, with the ability to lead their implementation.
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 procedure
Qualifications:- PreferredSMRP 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, 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 -Transport/Lifting - Frequently
Transport/Carrying - FrequentlyExerting Force/Pushing - FrequentlyExerting Force/Pulling - Frequently
Ascend/Descend - Frequently
Balancing - Occasionally
Position Self/Stooping - FrequentlyPosition Self/Kneeling - FrequentlyPosition Self/Crouching - Frequently
