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Vulcan Elements manufactures American rare-earth permanent magnets for defense, aerospace, and automotive applications. As a Senior Process Engineer, you will own the full lifecycle of a 1 million square foot manufacturing facility expansion—from design and equipment specification through installation, commissioning, production startup, and scale-up to full capacity.
You will be responsible for a designated process step, translating pilot-line processes into full-scale, stable, and repeatable production systems. This is a high-impact, high-ownership role requiring deep technical expertise and hands-on leadership.
Key responsibilities include:
- Run engineering trials to determine optimal equipment recipes and operating windows; own parameter definition for transitioning processes from development to stable, high-volume production
- Identify optimal ways to operate manufacturing equipment to maximize yield, improve throughput, and minimize scrap; monitor OEE results and station cycle times to drive continuous improvement
- Lead Gage R&R studies and capability studies (Cpk analysis) to ensure equipment and measurement systems meet tight product specifications
- Lead and own PFMEA (Process Failure Mode and Effects Analysis) for designated process steps to proactively identify and mitigate product and process risks
- Provide hands-on support during production startup, helping operators stabilize processes and eliminate early bottlenecks
- Review physical product quality at the station level, mapping defects back to root causes in machinery or process settings
- Ensure compliance with safety, environmental, and quality standards across all process activities
- Develop, review, or manage deliverables including risk assessments, ergonomic assessments, process flow charts, bill of process, station cycle times, process sheets, quality control plans, R&R studies, SOPs, work instructions, calibration procedures, and process monitoring plans
- Provide input on HMI controls logic, MES transaction lists, and process parameter tracking
- Support equipment development reviews and Factory Acceptance Tests (FATs) as needed (estimated <5% travel)
The role begins in Durham, NC and is expected to move to Benson, NC upon completion of the new facility.
REQUIREMENTS:
- Bachelor's degree in Chemical Engineering, Materials Science, Industrial Engineering, Mechanical Engineering, or related technical discipline with 5+ years of experience, OR Master's degree with 3+ years of experience
- Deep expertise running Design of Experiments (DoEs), Gage R&R studies, and statistical process control (SPC) to optimize high-precision manufacturing processes
- Expert-level experience authoring and developing standard manufacturing documents (PFMEA, Control Plans, Work Instructions, Process Flows)
- Proven track record of designing and running on-floor production trials to dial in complex equipment parameters without causing excessive downtime
- Must be a U.S. Person due to required access to U.S. export-controlled information or facilities
PREFERRED QUALIFICATIONS:
- Experience in heavy industrial manufacturing, metallurgy, magnetics, or chemical processing
- Six Sigma Green Belt or Black Belt certification
- Familiarity with MES (Manufacturing Execution Systems) implementation and automated transaction mapping
- Experience in highly regulated industries such as Defense (DoD), Aerospace (AS9100), or Automotive (IATF 16949)
PHYSICAL REQUIREMENTS:
Regular presence on the production floor with ability to navigate all facility areas. Must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. Role requires use of personal protective equipment including respirators, completion of fit testing, and adherence to all safety policies and regulatory requirements.
