Process Engineering Lead - High-Volume Manufacturing

Vulcan Elements; Benson (NC); On-site; USD 120,000 - 160,000; Full time

Job summary

Vulcan Elements is seeking a Staff Process Engineer to lead complex manufacturing processes from pilot development to stable high-volume production on the factory floor. You will act as the technical authority, solving tough problems and driving process capability.

You will design DoEs, analyze effects, support FAT/SAT, and develop PFMEAs, Control Plans, and SOPs while mentoring engineers and improving key metrics like FPY and OEE.

Qualifications

• Bachelor's degree in Engineering, Materials Science, or related field.
• 7+ years of process/manufacturing engineering experience.
• Hands-on experience taking processes from development through commissioning, qualification, and high-volume production.
• Strong knowledge of DoE, SPC, MSA, Gage R&R, Cp/Cpk, Pp/Ppk, ANOVA, regression, and statistical process analysis.
• Experience with PFMEAs, Control Plans, Process Flows, Process Specifications, and manufacturing documentation.
• Troubleshooting complex equipment and process problems on the manufacturing floor.
• Experience with Minitab or JMP preferred.
• Six Sigma Green Belt or Black Belt preferred.
• Experience in metallurgy, advanced materials, powder processing, high-temperature processing, automotive, aerospace, or other high-volume manufacturing preferred.

Responsibilities

• Develop equipment recipes, process parameters, operating windows, and production standards.
• Design and execute DoEs, analyze main effects/interactions, ANOVA, regression, and optimize critical process parameters.
• Support FAT/SAT, equipment startup, engineering trials, qualification runs, and production ramp.
• Perform Cp/Cpk, Pp/Ppk, SPC, control-chart, and process stability analysis.
• Lead MSA and Gage R&R studies to verify measurement repeatability and reproducibility.
• Develop and own Process Flows, PFMEA, Control Plans, BOP, Process Sheets, SOPs, Work Instructions, and Reaction Plans.
• Lead structured problem solving using 5-Why, Fishbone, Pareto, 8D, hypothesis testing, and statistical analysis.
• Improve FPY, scrap, rework, cycle time, OEE, throughput, and process capability.
• Identify CTQs and CPPs and establish monitoring, control limits, sampling plans, and reaction plans.
• Mentor engineers and review DoEs, PFMEAs, capability studies, process specifications, and technical investigations.

Skills

Hands-on leadership

Process optimization

Statistical analysis

DOE (Design of Experiments)

Quality improvement

Mentorship

Education

Bachelor's degree in Engineering, Materials Science, or related field

Tools

Minitab

JMP

Python

MATLAB

Job description

Vulcan Elements is seeking a Staff Process Engineer to lead complex manufacturing processes from pilot development to stable high-volume production on the factory floor. You will act as the technical authority, solving tough problems and driving process capability.

You will design DoEs, analyze effects, support FAT/SAT, and develop PFMEAs, Control Plans, and SOPs while mentoring engineers and improving key metrics like FPY and OEE.