Senior Process Engineer: Scale-Up & Manufacturing

Vulcan Elements Inc.; North Dakota; On-site; USD 120,000 - 160,000; Full time

Job summary

Vulcan Elements Inc. seeks a Senior Process Engineer to own and optimize full-scale production processes for a massive facility expansion. You will develop, install, and qualify production steps, translating pilot lines into stable, high-volume systems.

You will lead DoEs, PFMEA, and SPC initiatives, while coordinating with maintenance, quality, and operations to minimize downtime and ensure safety and regulatory compliance on the manufacturing floor.

Qualifications

• Bachelor’s degree in Chemical Engineering, Materials Science, Industrial Engineering, Mechanical Engineering, or related technical discipline with 5+ years or a Master’s with 3+ years.
• Deep expertise running DoEs, Gage R&R studies, and SPC to optimize high-precision manufacturing processes.
• Expert-level experience authoring PFMEA, Control Plans, Work Instructions, and Process Flows.

Responsibilities

• Run engineering trials to define optimal equipment recipes and windows for transition from development to high-volume production.
• Identify ways to maximize yield, improve throughput, and minimize scrap; monitor OEE and cycle times.
• Lead Gage R&R and capability studies to ensure measurement systems meet specs.
• Lead PFMEA for designated process steps to mitigate risks.
• Provide hands-on support during production startup to stabilize processes.
• Review product quality at station level and map defects to root causes.
• Ensure safety, environmental, and quality standards compliance across activities.
• Travel to support reviews and FATs (<5%).

Skills

DoE

Gage R&R

SPC

PFMEA

On-floor trials

Education

Bachelor’s in Engineering

Master’s degree

Tools

MES

Documentation tools

Job description

Vulcan Elements Inc. seeks a Senior Process Engineer to own and optimize full-scale production processes for a massive facility expansion. You will develop, install, and qualify production steps, translating pilot lines into stable, high-volume systems.

You will lead DoEs, PFMEA, and SPC initiatives, while coordinating with maintenance, quality, and operations to minimize downtime and ensure safety and regulatory compliance on the manufacturing floor.