Staff Manufacturing Engineer

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

Job summary

Vulcan Elements Inc. is seeking a Staff Manufacturing Engineer to drive the full lifecycle expansion of a 1 million square foot facility. You will own heavy production processes from design through startup, oversee vendor selection, and push process optimization.

You will lead safety, quality, and maintenance programs while working with R&D on future lines. Ideal candidates have a strong background in heavy industry equipment, PFMEA/Control Plans, and CAD proficiency for complex assemblies.

Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or related field with 7+ years of experience or Master's with 5+ years of experience.
• Hands-on CAD proficiency creating, modifying, and validating complex equipment assemblies.
• Proven track record in heavy custom equipment design, vendor management, and full-cycle commissioning for thermal or raw material processing.
• Ability to read, interpret, and create electrical schematics and pneumatic diagrams, including core engineering calculations.

Responsibilities

• Lead Equipment & Vendor Selection with technical and financial comparisons to meet scaling, quality, and budget goals.
• Own End-to-End Process Ownership from equipment design to production qualification for heavy production processes.
• Develop and optimize manufacturing processes, monitor OEE results, and drive yield improvements.
• Manage technical schedules, budgets, and deliverables aligned with milestones and customer commitments.
• Provide hands-on startup support to stabilize processes and eliminate bottlenecks.
• Collaborate with R&D to develop new processes and equipment strategies for future production lines.
• Ensure compliance with safety, environmental, and quality standards across all activities.
• Travel (<25%) to support reviews and FATs as needed.

Skills

CAD Proficiency

Equipment Design & Commissioning

Documentation Mastery

Technical Literacy

Education

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

Master's degree in related field

Job description

About Vulcan Elements

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.

The Role

As a Staff Manufacturing 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.

Core Expectations & Responsibilities

• Critical Priority - Equipment & Vendor Selection: Lead the evaluation, quote comparison, and selection of advanced manufacturing technologies and vendors. You will own the technical and financial side-by-side comparisons to ensure selected machinery meets our aggressive scaling and quality goals.

• End-to-End Process Ownership: Own equipment design/requirements, vendor performance and schedule, commissioning activities, process development, and production qualification for a major heavy production process (alloy production, casting, jet milling, powder production, pressing, and sintering operations).

• Process Optimization: Develop and optimize manufacturing processes to improve throughput, quality, and equipment reliability. Monitor OEE results and station cycle times to drive yield and capacity improvements.

• Project Management: Manage technical schedules, budgets, and deliverables aligned with company milestones and customer commitments.

• Hands-on Startup Support: Provide hands-on support during production startup, helping stabilize processes and eliminate early bottlenecks.

• Future Innovation: Develop and innovate new processes and equipment strategies (collaborating with R&D) to implement in future production lines, pushing Vulcan to achieve best-in-class magnet manufacturing.

• EHS & Quality Compliance: Ensure compliance with safety, environmental, and quality standards across all process activities.

• Travel: This position will require some interaction and travel to support equipment development reviews and Factory Acceptance Tests (FATs) as needed (estimated at <25% travel).

You will also be responsible for developing, reviewing, or managing the following deliverables:

• Risk & Safety: Risk Assessments, Ergonomic Assessments, PFMEA.

• Process Design: Line Layouts, Process Flow Charts, Bill of Process (BOP), Station Cycle Times, Process Sheets, and Simulations.

• Engineering Diagrams: CAD Drawings, Electrical & Pneumatic Drawings, and performing necessary Electrical and Pneumatic Calculations.

• Quality & Control: Quality Control Plans, R&R (Gage Repeatability and Reproducibility) Studies, Quality Checklists, and Process Checklists.

• Operations & Maintenance: Work Instructions (SOPs), Calibration Procedures, Spare Parts Lists, Bill of Materials (BOM), and Maintenance Manuals.

• Controls & IT: HMI Controls Manuals, Vision Programs, MES Transactions Lists.

Qualifications

• Education & Experience: Bachelor's degree in Mechanical Engineering, Materials Science, Metallurgical Engineering, or a related technical discipline with 7+ years of experience or Master's degree with 5+ years of experience.

• CAD Proficiency: Strong, hands-on experience creating, modifying, and validating complex equipment assemblies in CAD.

• Equipment Design & Commissioning: A proven track record in heavy custom equipment design, vendor management, and full-cycle commissioning for thermal or raw material processing.

• Documentation Mastery: Expert-level experience authoring and developing standard manufacturing documents (PFMEA, Control Plans, Work Instructions, and Process Flows).

• Technical Literacy: Ability to read, interpret, and create electrical schematics and pneumatic diagrams, including performing core engineering calculations (electrical/pneumatic).

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Qualifications

• Experience specifically in heavy industrial manufacturing, metallurgy, foundry operations, or chemical processing.
• Experience handling reactive powders or managing high-temperature vacuum furnace environments.
• Proficiency with advanced simulation software for workflow and line balancing.
• Familiarity with MES (Manufacturing Execution Systems) implementation and transaction mapping.