Process Engineer

About the role

Vulcan Elements is seeking a Process Engineer to play a vital role in the expansion of a large-scale manufacturing facility dedicated to producing American rare-earth permanent magnets. This position owns the execution of the facility's growth across the full lifecycle, encompassing design, equipment specification, production startup, and scaling operations for critical material streams. The hire will act as the primary technical leader ensuring that manufacturing processes are efficient, repeatable, and capable of meeting demanding production targets. They will leverage strong technical skills and leadership capabilities to translate process requirements into executable operational standards. This role requires a proactive problem-solver who can independently manage complex technical challenges while collaborating with cross-functional teams. The focus is on delivering robust and scalable process solutions that align with project timelines and quality objectives. Success in this position will be defined by the ability to stabilize high-volume production and drive continuous improvement initiatives.

Key facts

What you'll do

• Execute engineering trials that evaluate and confirm optimal equipment configurations and operational parameters required for a smooth transition from pilot scale to high-volume production.
• Optimize manufacturing processes to enhance product yield, increase throughput, and reduce material waste while monitoring overall equipment effectiveness (OEE) and cycle times for ongoing performance gains.
• Plan and oversee Gage R&R studies and capability analyses to verify that measurement systems and equipment consistently meet stringent product specifications and regulatory requirements.
• Own the management of the Process Failure Mode and Effects Analysis (PFMEA) for assigned processes to proactively identify, assess, and mitigate potential risks to product and process quality.
• Provide direct hands-on assistance during production startup phases, working closely with operators to stabilize processes and eliminate initial bottlenecks that hinder throughput.
• Analyze product quality data at the station level to trace defects back to root causes originating in machinery behavior or process settings.
• Ensure strict compliance with all safety, environmental, and quality standards during process implementation and daily operations on the shop floor.
• Participate actively in equipment development reviews and Factory Acceptance Tests (FATs), with travel expected to be less than 5% for project-related verification activities.
• Develop, review, and manage critical process documentation including Risk Assessments, Ergonomic Assessments, and PFMEA documentation.
• Create and maintain detailed Process Flow Charts, Bill of Process (BOP), Station Cycle Times, Process Sheets, and Process Checklists to guide operators.
• Produce and oversee Quality Control Plans, Gage R&R Studies, and Quality Checklists to ensure measurement integrity and consistent product quality.
• Draft Standard Operating Procedures (SOPs), Work Instructions, Calibration Procedures, and Process Monitoring plans that are clear, actionable, and compliant.
• Supply input on HMI Controls logic, MES Transactions Lists, and the tracking of critical process parameters to ensure data integrity and system alignment.
• Analyze trends in production data to drive adjustments in process parameters that improve consistency and reduce variability in output.
• Support the implementation of statistical process control (SPC) techniques to detect variation early and maintain tight control over critical process windows.
• Collaborate with equipment vendors and internal engineering teams to resolve issues during commissioning and routine process validation.
• Maintain accurate records of all process changes, trials, and outcomes to support audits, continuous improvement efforts, and knowledge transfer.
• Contribute to the creation of standardized work methods that promote safety, efficiency, and scalability across the manufacturing facility.
• Lead root cause investigations for quality issues, applying structured methodologies to prevent recurrence and ensure long-term process reliability.
• Serve as a key technical resource for operators and technicians, providing guidance and training on best practices for process execution and safety.

Requirements

• Hold a Bachelor's degree in Chemical Engineering, Materials Science, Industrial Engineering, Mechanical Engineering, or a related technical field with a minimum of 3 years of relevant experience in a manufacturing environment.
• Demonstrate proficiency in running Design of Experiments (DoEs), Gage R&R studies, and statistical process control (SPC) to enhance precision and consistency in manufacturing processes.
• Show extensive experience in creating and developing key manufacturing documents, including PFMEA, Control Plans, Work Instructions, and Process Flows, aligned with industry best practices.
• Possess a proven history of designing and executing production trials on the manufacturing floor to fine-tune complex equipment parameters without causing significant downtime or process disruptions.
• Exhibit strong analytical skills to interpret data, identify process variations, and implement corrective actions that improve yield and quality.
• Display a thorough understanding of quality management systems and the ability to apply standards that ensure compliance with safety and regulatory requirements.
• Have the ability to work independently and make sound technical decisions in a fast-paced manufacturing environment with shifting priorities.
• Communicate effectively both in writing and verbally to convey technical information clearly to cross-functional teams and stakeholders.

Nice to have

• Bring experience in heavy industrial manufacturing, metallurgy, magnetics, or chemical processing to accelerate process development and troubleshooting.
• Hold Six Sigma Green Belt or Black Belt certification, demonstrating a structured approach to process improvement and problem-solving.
• Show knowledge of MES (Manufacturing Execution Systems) implementation and automated transaction mapping to support digitalization efforts.
• Maintain a background in regulated industries such as Defense (DoD), Aerospace (AS9100), or Automotive (IATF 16949), ensuring familiarity with strict compliance requirements.

Practical notes

• This role requires regular presence on the production floor, necessitating the ability to navigate various areas of the facility.
• Candidates should be capable of climbing stairs, standing, and walking for extended periods as part of daily duties.
• The work environment may be hot, humid, or noisy, requiring adaptability to challenging physical conditions.
• The use of personal protective equipment, including respirators, is mandatory at all times when on-site.
• Adherence to all safety policies, procedures, and regulatory standards is essential for maintaining a safe working environment.
• Employees must complete required fit testing and wear appropriate PPE throughout their assigned tasks.
• Respond safely to changing conditions in the production environment to protect self and others.