Senior Industrial Engineer

About the role

Vulcan Elements is dedicated to the production of American-made rare-earth permanent magnets, playing a vital role in ensuring a secure and sustainable future. In the capacity of a Senior Industrial Engineer, you will be instrumental in the development of a significant manufacturing facility, focusing on optimizing layout design, planning capacity, and enhancing the overall flow of the factory. This position demands a robust analytical skill set and substantial experience in establishing new manufacturing operations.

Key facts

What you'll do

• Manage the comprehensive layout and spatial organization of a 1.1 million square foot facility, ensuring that production lines, storage areas, and logistics are strategically positioned for maximum efficiency.
• Conduct thorough capacity evaluations and cycle time analyses to identify inefficiencies and calculate factory throughput, aligning with scaling targets.
• Develop the Plan for Every Part (PFEP) and oversee internal material logistics, employing discrete-event simulations to model material handling processes and operator workflows.
• Create and maintain Yamazumi charts, line balance tables, and value stream maps to improve operational efficiency and reduce non-value-added activities.
• Formulate data-driven staffing models to accommodate varying production demands, assessing the needs for both direct labor and support staff as the facility expands.
• Act as the primary industrial engineering expert, working closely with Process, Equipment, Quality, and Operations teams to incorporate their requirements into the facility's overall design.
• Set up frameworks for 5S, visual management, and continuous improvement initiatives in preparation for mass production.
• Collaborate with cross-functional teams to ensure that engineering solutions are effectively implemented and aligned with production goals.
• Analyze production data to identify trends and areas for improvement, providing actionable insights to enhance operational performance.
• Lead training sessions for staff on best practices in industrial engineering and lean manufacturing principles.
• Participate in regular safety audits and ensure compliance with safety regulations throughout the facility.

Requirements

• A Bachelor's degree in Industrial Engineering, Systems Engineering, or a closely related technical discipline, with a minimum of 5 years of relevant experience, or a Master's degree with at least 3 years of experience.
• Proven track record in launching large-scale manufacturing operations from an industrial engineering standpoint, with documented success in previous projects.
• Expertise in creating Yamazumi charts, Value Stream Mapping (VSM), line balancing, and evaluating takt times against cycle times.
• Practical experience with advanced discrete-event simulation software (such as FlexSim, Arena, or Simio) for modeling factory operations, along with proficiency in AutoCAD for spatial design.
• Strong statistical analysis skills to evaluate machine standard minutes, operator efficiency, and equipment utilization metrics.
• Must be a U.S. Person due to the necessity of access to U.S. export-controlled information or facilities.

Nice to have

• Experience in large-scale manufacturing environments, particularly within heavy industrial sectors or automotive/aerospace gigafactories.
• Six Sigma Green Belt or Black Belt certification, or extensive training in lean manufacturing methodologies.
• Familiarity with racking systems, automated storage and retrieval systems (AS/RS), and compliance with regulations concerning chemical or hazardous material storage.
• Knowledge of highly regulated industries such as Defense (DoD), Aerospace (AS9100), or Automotive (IATF 16949).

Physical and Environmental Requirements

This position requires a regular presence on the production floor, necessitating the ability to navigate all areas of the facility. Candidates should be capable of climbing stairs, standing, and walking for extended periods, and working in environments that may be hot, humid, or noisy. The role mandates the use of personal protective equipment, including respirators, and adherence to all safety policies and regulations. Employees must complete fit testing and wear appropriate PPE during their assigned tasks while responding safely to changing conditions in the production environment.

If you are passionate about industrial engineering and eager to contribute to a pioneering company in the rare-earth magnet industry, we encourage you to apply for the Senior Industrial Engineer position at Vulcan Elements. Join us in shaping a resilient future through innovative manufacturing practices.