Pilot Operations Manager

Pilot Operations Manager

Research Triangle Park, NC

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. The Pilot Operations Manager is responsible for end-to-end execution of pilot-scale manufacturing for advanced rare earth materials, serving as the critical link between development and full-scale production. This role combines production leadership, process engineering, and material coordination to deliver qualified materials safely, on specification, and on schedule.

The leader will establish disciplined, scalable operations while partnering closely with development, commercial, quality, and EHS teams to enable rapid iteration, material qualification, and successful transition to production.

Responsibilities

• Own daily pilot manufacturing operations from planning through delivery, ensuring reliable, safe, and on-time execution of material and testing plans aligned with program and commercial priorities.
• Translate R&D processes into robust, repeatable pilot workflows; lead process optimization, troubleshooting, and continuous improvement to improve yield, stability, and scalability.
• Oversee end-to-end material flow including raw materials, work-in-process, and finished goods; coordinate staging, inventory, and movement of sensitive materials to align production output with testing and delivery requirements.
• Establish and enforce SOPs, work instructions, and standardized workflows; coordinate production schedules, resource allocation, and equipment readiness; implement and manage KPIs (yield, throughput, quality, schedule adherence) to drive performance and accountability.
• Ensure complete and accurate batch records, material qualification traveler sheets, and process documentation; synthesize and communicate clear material testing summaries to support data-driven decisions and stakeholder alignment.
• Maintain high-precision specifications through rigorous process control, in-process verification, and structured root cause and corrective action for deviations.
• Lead, coach, and develop a team of technicians; establish clear expectations for execution, safety, and documentation; build a culture of accountability, precision, and continuous improvement.
• Partner closely with development, commercial, quality, and EHS teams to align on priorities, communicate progress and risks, and ensure readiness for customer requirements and scale-up milestones.
• Integrate EHS requirements into all aspects of operations, including SOPs, training, material handling, and facility practices, ensuring safe and compliant execution at all times.

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

Qualifications

• Bachelor's degree in Materials Science, Chemical Engineering, Mechanical Engineering, or related field.
• 5+ years of experience in advanced materials, pilot production, or manufacturing environments.
• Proven experience leading pilot or production teams, with direct accountability for execution, safety, and performance.
• Hands-on experience working in pilot-scale or development environments, supporting process iteration, scale-up, and material qualification.
• Demonstrated experience in process engineering, pilot line operations, or scaling technologies from R&D to production.
• Strong track record of implementing SOP-driven operations, KPI management, and production documentation systems.
• Experience managing material flow, production scheduling, and cross-functional coordination.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

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.