Industrial Engineer

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 Senior Industrial Engineer, you will contribute to the full lifecycle of a massive 1.1 million square foot manufacturing facility expansion—focusing on the master layout, capacity planning, and total factory flow. You will be the primary thread connecting all departments, understanding 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

• Own the complete facility layout and space allocation across the 1.1M sqft footprint. Optimize the placement of production lines, raw material storage, shipping/receiving, and support infrastructure for optimal workflow.
• Conduct deep-dive capacity analyses and equipment cycle time studies to identify bottlenecks, calculate overall factory throughput, and ensure the site meets its aggressive scaling targets.
• Design the overall 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 across the factory.
• Create and maintain Yamazumi charts (operator workload balancing), line balance tables, and value stream maps to eliminate non-value-added time and optimize human-machine interactions.
• Develop data-driven headcount models for various production volumes, calculating both direct labor and indirect support staff requirements as the plant scales.
• Act as the central industrial engineering hub for the company—partnering directly with Process, Equipment, Quality, and Operations teams to understand and incorporate their specific spatial and utility needs into the master plan.
• Lay the groundwork for 5S, visual management, and continuous improvement (Kaizen) frameworks before mass production begins.

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

• Line Layouts (AutoCAD/FactoryCAD), Bill of Process (BOP), Station Cycle Times, Yamazumi Charts, and Material Flow Simulations.
• Ergonomic Assessments, Egress/Aisle Safety planning, and workflow PFMEA inputs.
• Input on standard work combinations, quality check visual management, and station checklists.