Staff Manufacturing Engineer

Vulcan Elements manufactures rare-earth permanent magnets for critical industries including defense, aerospace, and automotive.

The Role

As a Staff Manufacturing Engineer, you will contribute to the full lifecycle of a large-scale manufacturing facility expansion—from design and equipment specification through installation, commissioning, production startup, and scale-up to full capacity. You will translate pilot-line processes into stable, repeatable full-scale production systems.

Core Expectations & Responsibilities

• Lead evaluation, quote comparison, and selection of advanced manufacturing technologies and vendors.
• Own equipment design requirements, vendor performance, commissioning activities, process development, and production qualification for alloy production, casting, jet milling, powder production, pressing, and sintering operations.
• Develop and optimize manufacturing processes to improve throughput, quality, and reliability.
• Monitor OEE results and station cycle times to improve yield and capacity.
• Manage technical schedules, budgets, and deliverables aligned with company milestones.
• Provide hands-on support during production startup and process stabilization.
• Collaborate with R&D on future manufacturing process and equipment innovations.
• Ensure compliance with safety, environmental, and quality standards.
• Support equipment reviews and Factory Acceptance Tests (FATs) with up to 25% travel.

Deliverables

Risk & Safety

• Risk Assessments
• Ergonomic Assessments
• PFMEA

Process Design

• Line Layouts
• Process Flow Charts
• Bill of Process (BOP)
• Station Cycle Times
• Process Sheets
• Simulations

Engineering Diagrams

• CAD Drawings
• Electrical Drawings
• Pneumatic Drawings
• Electrical and Pneumatic Calculations

Quality & Control

• Quality Control Plans
• R&R Studies
• Quality Checklists
• Process Checklists

Operations & Maintenance

• Work Instructions (SOPs)
• Calibration Procedures
• Spare Parts Lists
• Bill of Materials (BOM)
• Maintenance Manuals

Controls & IT

• HMI Controls Manuals
• Vision Programs
• MES Transactions Lists

Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or related technical discipline with 7+ years of experience, or Master's degree with 5+ years of experience.
• Strong hands-on CAD experience with complex equipment assemblies.
• Experience in heavy custom equipment design, vendor management, and full-cycle commissioning for thermal or raw material processing.
• Expertise developing PFMEA, Control Plans, Work Instructions, and Process Flows.
• Ability to read and create electrical schematics and pneumatic diagrams and perform engineering calculations.
• Must be a U.S. Person due to access requirements for export-controlled information or facilities.

Preferred Qualifications

• Experience in heavy industrial manufacturing, metallurgy, foundry operations, or chemical processing.
• Experience handling reactive powders or high-temperature vacuum furnace environments.
• Proficiency with advanced simulation software for workflow and line balancing.
• Familiarity with MES implementation and transaction mapping.