Project Engineer

Job Summary:
The Project Engineer leads capital projects process improvements and equipment upgrades within a hightemperature metalmaking and alloy environment. This role bridges operations maintenance and technical engineering teams to ensure projects are delivered safely efficiently and with longterm reliability in mind. The ideal candidate is handson analytical and comfortable working in a heavy industrial setting.

As part of this role you will be required to travel to our UK site for an initial training period. During this time you will learn Less Common Metals processes standards and operating methods. You will then serve as the trainer and project team lead within Engineering for the US site once operations commence ensuring knowledge transfer and consistent global standards.

Key Responsibilities

Project Management

• Develop and manage project scopes budgets schedules and risk registers for projects.
• Coordinate internal stakeholders contractors and OEMs to ensure alignment and timely execution.
• Lead project meetings track milestones and provide progress reports to leadership.
• Oversee installation commissioning and handover of new equipment and systems.

Engineering & Technical Responsibilities

• Provide engineering support for melting casting rolling forging or heattreating operations.
• Analyse process data to identify bottlenecks inefficiencies and improvement opportunities.
• Support equipment specification design reviews and acceptance testing for furnaces cranes conveyors and automation systems.
• Conduct rootcause analysis (RCA) and implement corrective actions for equipment failures or process deviations.
• Ensure engineering documentation (P&IDs layouts manuals drawings) is accurate and up to date .

Safety & Compliance

• Ensure all project activities comply with site safety rules UK regulations and environmental standards.
• Lead hazard assessments (HAZOP HIRA PUWER) and implement engineering controls.
• Support continuous improvement of safety systems in hightemperature and highenergy environments.
• Promote a strong safety culture through proactive engagement and visible leadership.

Technical Team Collaboration

• Work closely with metallurgists process engineers and automation engineers to ensure project designs align with process requirements and product quality standards.
• Translate technical requirements into practical project deliverables ensuring equipment and systems meet metallurgical and operational specifications.
• Facilitate technical design reviews ensuring crossfunctional input is captured early to avoid rework.
• Partner with reliability engineers to incorporate predictive maintenance strategies condition monitoring and lifecycle considerations into project designs.
• Collaborate with maintenance engineering to ensure new equipment is maintainable accessible and supported with proper documentation and spareparts strategies.
• Support technical teams during trials commissioning and performance testing ensuring data is captured and analysed effectively.
• Act as a technical liaison between the facility and external engineering firms ensuring designs meet site standards and operational realities.

Technical Leadership

• Provide engineering judgement during troubleshooting shutdown planning and equipment upgrades.
• Ensure technical teams have the resources drawings and information needed to execute their work.
• Lead crossfunctional problemsolving sessions using tools such as 5Why FMEA and fishbone analysis.
• Mentor junior engineers and technicians on project execution technical standards and engineering best practices.

CrossFunctional Collaboration

• Work with operations to ensure project outcomes support production goals and operator usability.
• Coordinate with procurement on vendor selection contract negotiation and equipment sourcing.
• Support quality teams by ensuring new equipment meets product specifications and testing requirements.
• Communicate project impacts timelines and risks to all stakeholders.

Qualifications

Required

• Bachelors degree in mechanical Electrical Metallurgical or Industrial Engineering (or equivalent).
• 3 years of engineering experience in heavy industry (steel aluminum foundry forging or similar).
• Proven experience managing capital or processimprovement projects.
• Strong understanding of industrial equipment automation and reliability principles.
• Excellent communication planning and problemsolving skills.

Preferred

• Experience with molten metal handling refractory systems or furnace operations.
• Knowledge of lean manufacturing Six Sigma or TPM methodologies.
• Familiarity with CAD tools (AutoCAD SolidWorks) and project management software.
• Chartered Engineer (CEng) status or working toward it.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

The work environment will be a mix of a typical office environment a manufacturing floor and a construction site. Noise level: Normal office manufacturing and construction noises.

The above statements are intended to describe the general nature and level of work being performed by people assigned to this job. They are not intended to be an exhaustive list of all responsibilities duties skills required of personnel so classified. The reporting relationship may not reflect the most recent changes to the corporate reporting structure.

USA Rare Earth proudly supports Equal Employment Opportunities

USA Rare Earths policy is to provide equal employment opportunities to all applicants and will provide reasonable accommodations according to applicable federal state and/or local laws.

For assistance applying for employment through this site due to disability please contact Human Resources to discuss reasonable accommodations.

Required Experience:

IC