Senior Industrial Engineer

About the role

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. The company serves critical industries such as defense, aerospace, and automotive, with a focus on national security and economic resiliency.

As a Senior Industrial Engineer, you will contribute to the full lifecycle of a 1.1 million square foot manufacturing facility expansion, focusing on the master layout, capacity planning, and total factory flow. You will connect departments and understand their technical needs to optimize the physical and operational footprint. This is a high-impact, high-ownership role requiring deep analytical expertise and a proven history of setting up greenfield factories.

Responsibilities

• Master factory layout and space allocation: Own the complete facility layout and space allocation across the 1.1 million square foot footprint. Optimize the placement of production lines, raw material storage, shipping and receiving, and support infrastructure for workflow.
• Capacity and cycle time analysis: Conduct capacity analyses and equipment cycle time studies to identify bottlenecks, calculate factory throughput, and support the site's scaling targets.
• Material handling and flow simulation: Design the Plan for Every Part (PFEP) and internal material logistics. Run discrete-event simulations to model material movement, AGV traffic, forklift operations, and operator walk paths.
• Line balancing and lean tools: Create and maintain Yamazumi charts, line balance tables, and value stream maps to eliminate non-value-added time and optimize human-machine interactions.
• Headcount and labor estimates: Develop data-driven headcount models for various production volumes, calculating both direct and indirect labor estimates.

Key facts

• The role contributes to a 1.1 million square foot manufacturing facility expansion.
• Responsibilities include facility layout, capacity planning, and total factory flow.
• The role requires deep analytical expertise and a proven history of setting up greenfield factories.