Senior Process Engineer, Magnetics Manufacturing

Vulcan Elements Inc.; Benson (NC); On-site; USD 120,000 - 180,000; Full time

Job summary

Vulcan Elements Inc. in Durham, NC (moving to Benson, NC) seeks a Senior Process Engineer to own the transition from pilot to full-scale production at a 1 million sq ft facility expansion.

You will lead DoEs, SPC, and PFMEA, translating development processes into stable, high‑volume production systems with deep technical leadership. You will run trials, optimize equipment recipes, monitor OEE, support FATs, and ensure safety and quality compliance on the shop floor, with travel up to 5%.

Qualifications

• 5+ years of experience with DoEs, Gage R&R, and SPC to optimize high-precision manufacturing.
• Expert-level experience authoring PFMEA, Control Plans, Work Instructions, and Process Flows.
• Proven track record of running on-floor production trials to dial in complex equipment parameters.
• Must be a U.S. Person due to access to export-controlled information.

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 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 FATs (estimated <5% travel).

Skills

DoEs

Gage R&R

SPC

PFMEA

Process optimization

Education

Bachelor's degree in Chemical Engineering, Materials Science, Industrial Engineering, Mechanical Engineering, or related technical discipline

Master's degree with 3+ years of experience

Tools

MES

HMI Controls logic

Job description

Vulcan Elements Inc. in Durham, NC (moving to Benson, NC) seeks a Senior Process Engineer to own the transition from pilot to full-scale production at a 1 million sq ft facility expansion.

You will lead DoEs, SPC, and PFMEA, translating development processes into stable, high‑volume production systems with deep technical leadership. You will run trials, optimize equipment recipes, monitor OEE, support FATs, and ensure safety and quality compliance on the shop floor, with travel up to 5%.