Staff Process Engineer

About the role

Vulcan Elements is seeking a Staff Process Engineer to lead the development, commissioning, qualification, and scale‑up of complex manufacturing processes for rare‑earth permanent magnets. This hands‑on position works directly on the shop floor, translating engineering trials into stable, high‑volume production while ensuring statistical capability.

Key responsibilities

• Develop equipment recipes, process parameters, operating windows and production standards.
• Design and execute DoEs, perform ANOVA, regression and optimize critical process parameters.
• Support FAT/SAT, equipment start‑up, engineering trials, qualification runs and production ramp‑up.
• Conduct Cp/Cpk, Pp/Ppk, SPC and control‑chart analysis to assess process stability.
• Lead MSA and Gage R&R studies to verify measurement repeatability and reproducibility.
• Create and maintain Process Flows, PFMEAs, Control Plans, BOPs, SOPs and work instructions.
• Drive structured problem solving using 5‑Why, Fishbone, Pareto, 8D and hypothesis testing.
• Improve FPY, scrap, rework, cycle time, OEE, throughput and overall process capability.

Required profile

• Bachelor’s degree in Engineering, Materials Science or a related technical field.
• 7+ years of hands‑on process/manufacturing engineering experience, including scale‑up to high‑volume production.
• Proven ability to act as technical authority for manufacturing processes using data‑driven decision making.

Required skills

• Design of Experiments (DoE) and statistical analysis (ANOVA, regression).
• Statistical Process Control (SPC), capability analysis (Cp, Cpk, Pp, Ppk).
• Measurement System Analysis (MSA) and Gage R&R.
• Process Failure Mode Effects Analysis (PFMEA) and Control Plan development.
• Creation of Process Flows, SOPs, work instructions and equipment commissioning.