Senior Manager, Machining Operations

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.

This leader is hired before the machining equipment is installed and is accountable for building the organization, qualifying the process, and running it once it starts. That means owning equipment commissioning and process qualification from early engagement in the factory acceptance testing through first article and capability sign-off; designing the shift model, cell structure and technician progression; writing the training and onboarding programs that qualify every operator on the floor; and then owning safety, OEE, quality and the operating budget in steady state.

Responsibilities

Startup, Commissioning and Process Qualification

• Own machining process startup end to end — from equipment specification review and factory acceptance testing through installation, site acceptance, commissioning, process qualification and rate ramp.
• Partner with Manufacturing Engineering, Capital Execution and Automation & Digital Manufacturing on equipment selection, tooling and fixturing strategy, cell layout, and controls integration; serve as the operations acceptance authority for equipment turnover.
• Lead first-article inspection, process capability studies and Cpk qualification for each machining, grinding, coating and finishing operation before it is released to production.
• Partner with the Manufacturing Engineering team to establish coolant, handling, tooling and abrasive management systems from scratch, including the consumable strategy and vendor relationships behind them.
• Define the lot flow, WIP staging and buffer strategy through the area in partnership with Production Controls, and confirm it physically during construction rather than after turnover.
• Drive the ramp from first qualified part to full rate across nine production lines, sequencing capability build against the equipment delivery and line startup schedule.

Organization Design and Build

• Design the Machining Operations organization: shift model on a four-crew rotating schedule, cell and station structure, span of control, and the Shift Lead and Sr./Lead Technician layer that carries daily floor authority.
• Define technician roles and the progression path across stations — CNC machining, grinding, coating, tumbling, packaging and inspection — including the skill blocks that govern advancement.

Safe Operations

• Own safety performance and safety culture for the area, with visible presence on the floor and personal accountability for the conditions people work in.
• Partner with EHS on job hazard analysis, pre-startup safety review, and the machine-specific procedures that must exist before equipment is energized.
• Build the shift safety routines — pre-shift checks, near-miss reporting, hazard recognition coaching — and hold Shift Leads accountable for running them credibly.

Performance, OEE and Quality

• Own Overall Equipment Effectiveness for the area, and the availability, performance and quality components behind it. Establish the measurement method, data capture and loss taxonomy before startup so the baseline is trustworthy.
• Drive first-pass yield, scrap and rework reduction, cycle time and changeover performance, using structured problem solving on the largest recurring losses.
• Own dimensional and cosmetic quality outcomes in partnership with Quality — control plans, SPC on critical characteristics, in-line inspection strategy and material disposition.

Operating Budget and Resource Management

• Own the Machining Operations operating expense budget: direct and indirect labor, overtime, tooling and abrasives, coolant and consumables, plating chemistry, and supplies.
• Build the area cost model and headcount plan through the ramp, and manage to it with monthly variance explanation and corrective action.
• Manage tooling and consumable spend as a controllable — vendor strategy, tool life management, regrind and reconditioning programs — since it is among the largest levers in a precision machining operation.

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

Qualifications

Required

• Bachelor’s degree in Mechanical Engineering or a related technical discipline
• 8+ in precision machining or discrete manufacturing operations, including five or more years leading production teams in a 24/7 multi-shift environment.
• Deep working knowledge of CNC machining and precision grinding — setup, tooling, fixturing, feeds and speeds, tool life, and the drivers of dimensional variation.
• Strong command of GD&T, dimensional metrology, process capability (Cpk) and statistical process control.
• Demonstrated ownership of equipment commissioning and process qualification — you have brought new machining equipment from installation through first article and capability sign-off.
• Demonstrated ownership of OEE or equivalent equipment performance metrics, including establishing the measurement method rather than inheriting one.
• Direct accountability for safety performance in a machining or metalworking environment, including machine guarding, LOTO and chemical handling.
• Operating budget ownership with demonstrated cost control, particularly of labor and consumable spend.

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

Preferred

• Greenfield, startup or major expansion experience — standing up a machining operation from an empty building rather than improving a running one.
• Experience machining brittle, hard or magnetic materials; familiarity with rare earth magnet machining and pyrophoric swarf handling is a significant advantage.
• Experience with electroplating or surface finishing operations, including chemical handling and wastewater considerations.
• Lean or Six Sigma certification (Green Belt or higher) with a record of applied projects in a machining environment.
• Experience deploying MES, shop-floor data collection or automated inspection systems.

Physical and Environmental Requirements

The position requires regular presence on the production floor and the ability to navigate all areas of the facility. Candidates must be able to climb stairs, stand and walk for extended periods, and work in environments that may be hot, humid, or noisy. The role also requires the use of personal protective equipment, including respirators, and adherence to all applicable safety policies, procedures, and regulatory requirements. Employees must be able to complete required fit testing, wear appropriate PPE for the duration of assigned tasks, and respond safely to changing conditions within the production environment.