Process Engineer

Process Engineer

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 Role

As a 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.

Core Expectations & Responsibilities

• Process Development & Qualification: 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.
• Process Optimization: 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.
• Quality & Capability Assurance: Lead Gage R&R studies and capability studies (Cpk analysis) to ensure equipment and measurement systems are capable of meeting tight product specifications.
• Risk Management: 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.
• Hands-on Startup Support: Provide hands-on support during production startup, helping operators stabilize processes and eliminating early bottlenecks.
• Product & Process Review: Dedicate time to reviewing physical product quality at the station level, mapping defects back to root causes in the machinery or process settings.
• EHS & Quality Compliance: Ensure compliance with safety, environmental, and quality standards across all process activities.
• Travel: 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 & Safety: Risk Assessments, Ergonomic Assessments, and PFMEA.
• Process Design: Process Flow Charts, Bill of Process (BOP), Station Cycle Times, Process Sheets, and Process Checklists.
• Quality & Control: Quality Control Plans, R&R (Gage Repeatability and Reproducibility) Studies, and Quality Checklists.
• Operations & Maintenance: Standard Operating Procedures (SOPs), Work Instructions, Calibration Procedures, and Process Monitoring plans.
• Controls & IT: Input on HMI Controls logic, MES Transactions Lists, and process parameters tracking.

Qualifications

• Education & Experience: Bachelor's degree in Chemical Engineering, Materials Science, Industrial Engineering, Mechanical Engineering, or a related technical discipline with 3 + years of experience.
• Process & Statistical Mastery: Deep expertise running DoEs (Design of Experiments), Gage R&R studies, and statistical process control (SPC) to optimize high-precision manufacturing processes.
• Documentation Expert: Expert-level experience authoring and developing standard manufacturing documents (PFMEA, Control Plans, Work Instructions, and Process Flows).
• Trial Execution: Proven track record of designing and running on-floor production trials to dial in complex equipment parameters without causing excessive downtime.

Good to Have (Preferred Skills)

• 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).