Senior Process Engineer

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. With a focus on national security and economic resiliency, we serve critical industries such as defense, aerospace, and automotive powering a high-technology future. Vulcan Elements is building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency. 

As a Senior Process Engineer, you will contribute to the full lifecycle of a massive 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 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 leadership. 

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility. 

Responsibilities 

• Run engineering trials to determine optimal equipment recipes and operating windows. Own the parameter definition required to transition processes from development to stable, high-volume production. 
• Identify the best 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 are capable of meeting tight product specifications. 
• Lead and own the PFMEA (Process Failure Mode and Effects Analysis) for your designated process steps to proactively identify and mitigate product and process risks. 
• Provide hands-on support during production startup, helping operators stabilize processes and eliminating early bottlenecks. 
• Dedicate time to reviewing physical product quality at the station level, mapping defects back to root causes in the machinery or process settings. 
• Ensure compliance with safety, environmental, and quality standards across all process activities. 
• This position will require some interaction and travel to support equipment development reviews and Factory Acceptance Tests (FATs) as needed (estimated at <5% travel). 

You will also be responsible for developing, reviewing, or managing the following deliverables: 

• Risk Assessments, Ergonomic Assessments, and PFMEA. 
• Process Flow Charts, Bill of Process (BOP), Station Cycle Times, Process Sheets, and Process Checklists. 
• Quality Control Plans, R&R (Gage Repeatability and Reproducibility) Studies, and Quality Checklists. 
• Standard Operating Procedures (SOPs), Work Instructions, Calibration Procedures, and Process Monitoring plans. 
• Input on HMI Controls logic, MES Transactions Lists, and process parameters tracking. 

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.   

Qualifications 

• Bachelor’s degree in Chemical Engineering, Materials Science, Industrial Engineering, Mechanical Engineering, or a related technical discipline with 5+ years of experience OR a Master’s degree with 3+ years of experience. 
• Deep expertise running DoEs (Design of Experiments), 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, and 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 specifically 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 and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.