Senior Process Engineer

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.

As a Senior 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.

This role begins in Durham, NC and is expected to move to Benson, NC upon completion of new facility.

Responsibilities

• 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.
• 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.
• Lead Gage R&R studies and capability studies (Cpk analysis) to ensure equipment and measurement systems are capable of meeting tight product specifications.
• 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.
• Provide hands-on support during production startup, helping operators stabilize processes and eliminating early bottlenecks.
• Dedicate time to reviewing physical product quality at the station level, mapping defects back to root causes in the machinery or process settings.
• Ensure compliance with safety, environmental, and quality standards across all process activities.
• This position will require some interaction and travel to support equipment development reviews and Factory Acceptance Tests (FATs) as needed (estimated at