Senior Manager, Machining Operations

Vulcan Elements; Benson (NC); On-site; USD 180,000 - 230,000; Full time

Job summary

Vulcan Elements in Benson, NC seeks an experienced Operations Leader to build and scale its Machining Operations for American rare-earth magnets. You will own equipment commissioning, process qualification, and the ramp from startup to full-rate production.

This role designs the shift model, cell structure and technician progression; writes training programs; ensures safety, OEE, quality, and budget controls; collaborates with Manufacturing Engineering, Capital Execution, and Automation to

Responsibilities

• Own machining process startup end to end — from equipment specification review to rate ramp.
• Partner with Manufacturing Engineering, Capital Execution and Automation & Digital Manufacturing on tooling strategy and cell layout.
• Lead first-article inspection, process capability studies and CpK qualification for each operation.
• Define coolant, handling, tooling and abrasive management systems with consumable strategy and vendor relationships.
• Define lot flow, WIP staging and buffer strategy with Production Controls; verify during construction.
• Drive ramp from first qualified part to full rate across nine production lines.
• Design Machining Operations organization: shift model, cell structure, span of control, and leadership layers.
• Define technician roles and progression across CNC machining, grinding, coating, tumbling, packaging and inspection.
• Own safety performance and culture; partner with EHS on hazard analysis and startup safety procedures.
• Own OEE, quality metrics and continuous improvement; establish loss taxonomy and measurement baseline.
• Own machining operations budget: labor, tooling, consumables, and overhead; manage headcount and costs.

Job description

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.

This leader is hired before themachiningequipment is installed and is accountable for building the organization, qualifying the process, and running it once it starts.That means owning equipment commissioning and processqualification fromearly engagement in thefactory acceptancetestingthrough first article and capability sign-off; designing the shift model, cell structure and technician progression; writing the training and onboarding programs that qualify every operator on the floor; and then owning safety, OEE, quality and the operating budget in steady state.

Responsibilities

Startup, Commissioning and Process Qualification

• Own machining process startup end to end — from equipment specification review and factory acceptance testing through installation, site acceptance, commissioning, processqualificationand rate ramp.
• Partner with Manufacturing Engineering, Capital Execution and Automation & Digital Manufacturing on equipmentselection, tooling and fixturing strategy, cell layout, and controls integration; serve as the operations acceptance authority for equipment turnover.
• Lead first-article inspection, process capabilitystudiesandCpkqualification for each machining, grinding,coatingand finishing operation before it is released to production.
• Partner with the Manufacturing Engineering team toestablishcoolant,handling,toolingand abrasive management systems from scratch, including the consumable strategy and vendor relationships behind them.
• Define the lot flow, WIP staging and buffer strategy through the area in partnership with ProductionControls, andconfirm it physically during construction rather than after turnover.
• Drive the ramp from first qualified part to full rate across nine production lines, sequencing capabilitybuildagainst the equipment delivery and line startup schedule.

Organization Design and Build

• Design the Machining Operations organization: shift model on a four-crew rotating schedule,celland station structure, span of control, and the Shift Lead and Sr./Lead Technician layer that carries daily floor authority.
• Define technician roles and the progression path across stations — CNC machining, grinding, coating, tumbling,packagingand inspection — including the skill blocks that govern advancement.

Safe Operations

• Own safety performance and safety culture for the area, with visible presence on the floor and personal accountability for the conditions people work in.
• Partner with EHS on job hazard analysis, pre-startup safety review, and the machine-specific procedures that must exist before equipment is energized.
• Build the shift safety routines — pre-shift checks, near-miss reporting, hazard recognition coaching — and hold Shift Leads accountable for running them credibly.

Performance, OEE and Quality

• Own Overall Equipment Effectiveness for the area, and the availability,performanceand quality components behind it. Establish the measurement method, datacaptureand loss taxonomy before startup so the baseline is trustworthy.
• Drive first-pass yield, scrap and rework reduction, cycletimeand changeover performance, using structured problem solving on the largest recurring losses.
• Own dimensional and cosmetic quality outcomes in partnership with Quality — control plans, SPC on critical characteristics, in-line inspection strategy and material disposition.

Operating Budget and Resource Management

• Own the Machining Operations operating expense budget: direct and indirect labor, overtime, tooling and abrasives, coolant and consumables, plating chemistry, and supplies.
• Build the area cost model and headcount plan through theramp, andmanage to it with monthly variance explanation and corrective action.
• Manage tooling and consumablespend as a controllable — vendor strategy, tool life management, regrind and reconditioning programs — since it is