Senior Industrial Engineer

The role

You will contribute to the full lifecycle of a 1.1 million square foot manufacturing facility expansion. You will focus on master layout, capacity planning, and total factory flow.

What you will do

• Own the complete facility layout and space allocation across the 1.1M sqft footprint.
• Conduct capacity analyses and equipment cycle time studies.
• Design the Plan for Every Part and internal material logistics.
• Run discrete-event simulations to model material movement.
• Create Yamazumi charts, line balance tables, and value stream maps.
• Develop data-driven headcount models for various production volumes.
• Partner with Process, Equipment, Quality, and Operations teams.
• Lay the groundwork for 5S, visual management, and continuous improvement frameworks.
• Develop and manage deliverables including Line Layouts, BOP, and Station Cycle Times.
• Perform Ergonomic Assessments and Egress/Aisle Safety planning.

Required qualifications

• Bachelor’s degree in Industrial Engineering, Systems Engineering, or a related technical discipline with 5+ years of experience OR a Master’s degree with 3+ years of experience.
• Proven, hands-on experience actively setting up a new, large-scale manufacturing facility from the ground up.
• Expert capability in developing Yamazumi charts, Value Stream Mapping (VSM), line balancing, and calculating takt times vs. cycle times.
• Direct experience using advanced discrete-event simulation software (e.g., FlexSim, Arena, Simio).
• Proficiency in AutoCAD for massive spatial layouts.
• Strong background using statistical analysis to calculate machine standard minutes, operator efficiency, and equipment utilization rates.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.
• Ability to climb stairs, stand and walk for extended periods.
• Ability to work in environments that may be hot, humid, or noisy.
• Ability to use personal protective equipment, including respirators.

Nice to have

• Experience specifically in massive-scale facilities, heavy industrial manufacturing, or automotive/aerospace gigafactories.
• Six Sigma Green Belt or Black Belt, or heavy lean manufacturing training.
• Familiarity with racking systems, automated storage and retrieval systems (AS/RS), and specialized chemical or hazardous material storage regulations.
• Experience in highly regulated industries such as Defense (DoD), Aerospace (AS9100), or Automotive (IATF 16949).

About the company

Vulcan Elements is manufacturing American rare-earth permanent magnets for a secure, resilient future. They serve critical industries such as defense, aerospace, and automotive.