Asphalt Process Engineer I

Introduction

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.

Summary

The Asphalt Process Engineer is responsible for ensuring the safety, quality, and reliability of the asphalt yard processes to meet asphalt supply demands. He/she will develop, implement and execute process improvement projects with the goal of increasing efficiency, reliability and profitability while reducing process variation. When applicable, the Asphalt Process Engineer will execute approved capital improvements by coordinating with the Asphalt Operations Manager, Plant Engineering Manager and department managers on timelines, budget and resources needed. The Asphalt Process Engineer will use a hierarchy of values (Safety, Quality, Service and Cost) in prioritizing his/her activities, while supporting plant goals and improvement plans.

Essential Duties

Specific responsibilities include, but are not limited to:

40% - Provide a safe workplace through adherence to company safety policies, housekeeping and defined standards of training.

• Ensure compliance to safety policies and procedures. Promote a culture of a safe and clean work environment where safety is the highest priority.
• Conduct inspections of plant areas and ensure corrective actions are taken to investigate and resolve safety/quality/reliability/process related issues.
• Champions investigation of safety incidents and root cause analysis to help improve site and processes.
• Provide input and participate in production crew safety meetings to ensure operator engagement in the plant safety programs.
• Demonstrate a high level of commitment to safety and be a leader in the areas of housekeeping and organization.

60% - Develop, implement and execute process improvement projects and plant capital projects.

• Support strategic projects and plant initiatives.
• Implement company and industry best practices.

• Communicate effectively with the management team regarding resources needed to ensure the timely and accurate execution of process improvement projects.
• Work with the Asphalt Operations Manager and Plant Engineering Manager to prepare and submit requests for capital expenditures.
• Identify critical equipment and ensure effective PM strategy and schedule.
• Collaborate with Maintenance, Capital Delivery Engineers, and Reliability Engineers to effectively and economically improve equipment and process designs.
• Support all plant product qualifications, process capability studies, raw materials trial /qualifications and product development /improvement projects.
• Support all R&D and Plant trial requests (PTR’s). Ensure that trials are accurately conducted employing the latest PTR protocol (w/potential problem analysis) and reported per required standards, timelines and accounting cycles.
• Identify production or process problems and prepare /implement solutions as needed, using standard PI tools such as QualPro, MVT/DOE and Kepner-Tregoe problem solving techniques.
• Performs PPA /FMEA on all major process and raw material changes including documentation for the changes on updated P&IDs.
• Manage the application and interpretation of SPC charting and teach all machine operators the benefits of the tool and how to input data.
• Comply with and enforce established quality policies and procedures.
• Conduct compliance audits of raw material asphalt testing, process specifications, plant change notices (PCN’s) and other in-plant processes.
• Coordinate required inspections of tanks, pressure vessels, fired heaters and other critical equipment.
• Participate in plant technical support activities as required to achieve plant goals.
• Lead the integration of Braincube into the asphalt yard operation to analyze inputs/outputs to optimize processes, reduce abnormalities, and drive down variability.
• Perform other duties as assigned.

Physical Demands

• Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
• Frequent sitting, walking and standing; occasional climbing, stooping, kneeling, crouching, crawling and balancing.
• Oral and auditory capacity enabling interpersonal communication as well as communication through automated devices such as the telephone.
• Required to sit, stand, walk and use hands to grasp, handle or feel objects, tools and product samples.

• Specific vision abilities required by this job include close vision, peripheral vision, depth perception and the ability to adjust focus.
• Must have the ability to differentiate colors precisely.
• Required to reach with hands and arms and stoop, kneel or crouch.
• Ability to perform detailed testing processes in various process conditions.
• Frequent use of eye, hand and finger coordination enabling the use of manufacturing equipment and machinery.
• Ability to read and concentrate via computer data entry typing and proofreading.
• Ability to lift and/or move up to 25 pounds and occasionally up to 50 pounds.

Under This Roof, We Require

• A BS degree in Engineering, ChE or ME preferred.
• Demonstrated process engineering experience in a manufacturing environment. Experience in refining or chemical manufacturing is preferred.
• The ideal candidate will possess a strong commitment to safety and have experience with manufacturing controls (preferably PLC and HMI). Demonstrated knowledge of engineering fundamentals is required.

Under This Roof, We Also Value

• Ability to quickly identify safety hazards and make clear recommendations to resolve.
• Ability to perform troubleshooting and solve complicated production challenges.
• Familiar with standard manufacturing concepts, practices and procedures.
• Communication skills and the ability to work well with employees at all levels of the organization, as well as outside contractors and vendors.
• Computer skills, including G Suite, WinSPC, AutoCAD, Braincube as well as the ability to quickly learn and master plant specific programs.
• Strong data analysis skills. Spreadsheet design and data manipulation/analysis a plus.
• Strong problem solving skills and techniques, with an emphasis on the use of techniques such as PPA, MVT/DOE and Kepner-Tregoe.
• Ability to respond to requests in a professional and timely manner.
• Strong planning, prioritization, organizational and reporting skills.
• Independent problem-solving skills.
• Positive attitude, ability to adapt and contribute to a team environment is critical.

How We Protect What Matters Most

• We offer a wide range of health insurance options that include medical, dental, and vision for you and your family.