vulcanelements · Research Triangle Park, NC · Durham, North Carolina, United States
<p><span data-contrast="auto">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 including defense, aerospace, and automotive. </span><span data-contrast="auto">We are building a team of ambitious professionals committed to Mission Focus, Technical Excellence, and Transparency.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></p> <p><span data-contrast="auto">As a Staff Process Engineer,</span><span data-contrast="auto"> you will serve as a technical leader responsible for developing, commissioning, qualifying, and scaling complex manufacturing processes from pilot-scale development into stable, repeatable high-volume production. </span><span data-contrast="auto">This is a highly hands-on role. You will work directly on the manufacturing floor during equipment commissioning and production ramp, designing engineering trials, developing process recipes, establishing operating windows, solving complex process problems, and proving that manufacturing processes are statistically capable.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></p> <p><span data-contrast="auto">You will be expected to become the </span><span data-contrast="auto">technical authority for assigned manufacturing processes</span><span data-contrast="auto">, using data, experimentation, and fundamental engineering principles to drive decisions.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></p> <p><strong><span data-contrast="auto">Core Responsibilities</span></strong><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></p> <ul> <li><span data-contrast="auto">Develop equipment recipes, process parameters, operating windows, and production standards.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Design and execute DoEs, analyze main effects/interactions, ANOVA, regression, and optimize critical process parameters.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Support FAT/SAT, equipment startup, engineering trials, qualification runs, and production ramp.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Perform Cp/Cpk, Pp/Ppk, SPC, control-chart, and process stability analysis.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Lead MSA and Gage R&R studies to verify measurement repeatability and reproducibility.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Develop and own Process Flows, PFMEA, Control Plans, BOP, Process Sheets, SOPs, Work Instructions, and Reaction Plans.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Lead structured problem solving using 5-Why, Fishbone, Pareto, 8D, hypothesis testing, and statistical analysis.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Improve FPY, scrap, rework, cycle time, OEE, throughput, and process capability.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Identify CTQs and Critical Process Parameters (CPPs) and establish monitoring, control limits, sampling plans, and reaction plans.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Mentor engineers and review DoEs, PFMEAs, capability studies, process specifications, and technical investigations.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> </ul> <p><em><span data-contrast="auto">Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business. </span></em><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></p> <p><strong><span data-contrast="auto">Qualifications</span></strong><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></p> <ul> <li><span data-contrast="auto">Bachelor's degree in Engineering, Materials Science, or related technical field with 7+ years of process/manufacturing engineering experience.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Strong hands-on experience taking processes from development through commissioning, qualification, and high-volume production.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Deep knowledge of DoE, SPC, MSA, Gage R&R, Cp/Cpk, Pp/Ppk, ANOVA, regression, and statistical process analysis.</span><span data-ccp-props="{"335551550":6,"335551620":6}"> </span></li> <li><span data-contrast="auto">Strong experience developing PFMEAs, Control Plans, Process Flows, Process Specifications, and manufacturing documentation.<