Senior Simulation Engineer Jobs in Mebane, NC (NOW HIRING)

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.  

As a Sr. 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.  

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 production process (alloy production, casting, powder production, pressing, sintering, machining, coating, testing, packaging, etc.). 

• 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 <10% 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.  

Responsibilities and tasks outlined are not exhaustive and may change as determined by the needs of the business.  

Qualifications 

• Education & Experience: Bachelor's degree in Mechanical Engineering or a related technical discipline with 5+ years of experience OR a Master's degree with 3+ 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 custom equipment design, vendor management, and full-cycle commissioning for various industrial processes. 

• 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).  

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

Preferred Qualifications 

• Experience specifically in heavy industrial manufacturing, metallurgy, magnetics, or chemical processing. 

• Proficiency with advanced simulation software for workflow and line balancing. 

• Hands-on experience with machine vision programming (e.g., Cognex, Keyence). 

• Familiarity with MES (Manufacturing Execution Systems) implementation and transaction mapping. 

• Experience in highly regulated industries such as Defense (DoD), Aerospace (AS9100), or Automotive (IATF 16949).