Metrology Lead

About the role

At Vulcan Elements, our mission is to manufacture American-made rare-earth permanent magnets, which play a crucial role in bolstering national security and supporting economic growth. Our focus spans essential industries such as defense, aerospace, and automotive, as we strive to create a technologically advanced future. We are in the process of building a team of dedicated professionals who are committed to achieving our mission objectives with precision and transparency. The Metrology Lead will play a pivotal role in our Pilot operations in Durham, with a planned transition to Benson in early 2027. This position is vital for developing and managing measurement systems that ensure product quality throughout the entire production lifecycle, from initial development to high-volume manufacturing. The Metrology Lead will work closely with various teams, including the Analytical Laboratory, R&D, Engineering, Manufacturing, and Supply Chain, to create a robust metrology strategy.

Key facts

What you'll do

• Assess and analyze existing metrology capabilities to ensure they meet product, process, and customer specifications.
• Develop a comprehensive metrology roadmap to support Pilot operations and future large-scale manufacturing efforts.
• Set measurement criteria for Critical-to-Quality (CTQ) features identified through Process Failure Mode and Effects Analysis (PFMEA) and Control Plans.
• Design measurement methodologies and sampling strategies that align with Control Plans.
• Ensure measurement capabilities are in sync with production goals and process readiness.
• Oversee the selection, specification, procurement, installation, and qualification of metrology instruments.
• Create protocols for equipment qualification and establish acceptance criteria.
• Collaborate with the Analytical Laboratory to develop and validate inspection and measurement methodologies.
• Perform Gauge Repeatability and Reproducibility (Gauge R&R), bias, linearity, and stability evaluations.
• Assess measurement uncertainty where applicable.
• Manage calibration, preventive maintenance, and lifecycle management of quality inspection tools.
• Assist in the development and implementation of Statistical Process Control (SPC) strategies for operational efficiency.
• Conduct process capability studies (Cp, Cpk) and analyze quality data to pinpoint areas for improvement.
• Standardize measurement practices across various facilities.
• Lead the installation and qualification of metrology equipment at the Benson facility.
• Facilitate the transition of validated inspection methods from Pilot operations to the Benson site.
• Develop standard operating procedures (SOPs), work instructions, and training materials for staff.
• Support the implementation of ISO 9001 and related measurement processes.
• Establish laboratory and metrology practices that align with ISO/IEC 17025 principles where applicable.
• Aid in internal and customer audits, as well as initiatives aimed at continuous improvement.

Responsibilities and tasks may evolve based on business needs.

Requirements

• A Bachelor's degree in Chemistry, Engineering, Materials Science, Physics, or a related technical discipline.
• At least 7 years of experience in manufacturing quality, metrology, or measurement systems; candidates with advanced degrees (M.S. or Ph.D.) may be considered with less experience.
• Significant experience in the development of analytical methods.
• Strong proficiency in Measurement System Analysis (MSA) and Statistical Process Control (SPC).
• Experience in selecting and qualifying metrology equipment is essential.
• Familiarity with ISO 9001 and measurement system standards is required.
• Understanding of ISO/IEC 17025 laboratory principles is a plus.
• Proven experience in supporting new product introductions and scaling manufacturing processes effectively.
• Excellent statistical analysis and problem-solving skills are necessary.

Candidates must be U.S. Persons due to the requirement for access to U.S. export-controlled information or facilities.

Nice to have

• Experience with advanced statistical software tools for data analysis.
• Knowledge of Six Sigma methodologies and certifications.
• Familiarity with lean manufacturing principles and practices.
• Previous experience in the rare-earth magnet industry or related fields.
• Understanding of regulatory compliance and quality assurance processes.

Skills & tools

• Proficient in statistical analysis software (e.g., Minitab, JMP).
• Familiarity with CAD software for metrology equipment design.
• Strong communication and interpersonal skills for effective collaboration.
• Ability to work independently and manage multiple projects simultaneously.
• Strong organizational skills and attention to detail.

Practical notes

This position is based in Research Triangle Park, NC, with a full-time commitment. The role offers a competitive salary, commensurate with experience, and includes benefits. The Metrology Lead will initially work in Durham, transitioning to Benson in early 2027. This is an exciting opportunity to contribute to a company at the forefront of technology and innovation in the rare-earth magnet sector.