Process Engineer in Sumter, South Carolina at VAC Magnetics LLC

eVAC Magnetics LLC
Job Description

Overview:

The Process Engineer – Mechanical Processing is responsible for the technical ownership, stability, capability, and continuous improvement of all finishing processes within the manufacturing operation. This position serves as the subject matter expert for grinding, cutting, surface finishing, inspection technologies, cleaning, coating, marking, and packaging processes used in the production of powder metallurgy components and magnetic systems. The Process Owner drives process development, equipment optimization, manufacturing excellence, root cause analysis, and implementation of new manufacturing technologies while ensuring safe, efficient, and repeatable production processes. This role works closely with Production, Quality, Equipment Engineering, Automation, Maintenance, and Supply Chain to support customer requirements, operational goals, and business growth.

KEY RESPONSIBILITIES include but are not limited to the following:

1. Process Ownership

• Serve as the technical owner for Final manufacturing processes.
• Establish, maintain, and continuously improve manufacturing standards and process specifications.
• Define critical process parameters and ensure process compliance.
• Review, approve, and implement process changes.
• Monitor and improve process capability, repeatability, and long-term process stability.
• Develop and maintain standard operating procedures, work instructions, and process documentation.

1. Continuous Improvement & Operational Excellence

• Lead continuous improvement initiatives focused on safety, quality, delivery, and cost.
• Identify and implement productivity, yield, and throughput improvements.
• Drive waste elimination and cost reduction projects.
• Utilize statistical data analysis and process monitoring tools to improve manufacturing performance.
• Support Lean Manufacturing and Six Sigma initiatives.

1. Process Development & Industrialization

• Lead development and implementation of new manufacturing technologies.
• Plan, execute, and evaluate manufacturing trials and process validation activities.
• Support new product introductions and product transfer activities.
• Participate in equipment specification, design reviews, commissioning, and startup activities.
• Develop optimized manufacturing concepts for future growth and capacity expansion.

1. Quality & Technical Problem Solving

• Lead root cause investigations for process failures, scrap, customer complaints, and non-conforming product.
• Develop and implement corrective and preventive actions.
• Support PFMEA, Control Plans, SPC, Process Capability Studies, and Validation Activities.
• Analyze production and quality data to identify trends and improvement opportunities.
• Act as technical support during customer audits and quality investigations.

1. Manufacturing Support

• Provide technical support to production and maintenance teams.
• Troubleshoot complex process and equipment issues.
• Support equipment reliability and manufacturing up-time initiatives.
• Develop and deliver technical training for operators, technicians, and supervisors.
• Interface with equipment suppliers, tooling vendors, and external technical resources.

1. Safety & Compliance

• Ensure all manufacturing activities comply with company safety policies and regulatory requirements.
• Participate in risk assessments and machine safety reviews.
• Promote safe work practices throughout the manufacturing area.
• Support environmental, health, and safety initiatives.

REQUIRED QUALIFICATIONS:

• Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, Materials Engineering, Industrial Engineering, or related technical discipline.
• Minimum five (5) years of manufacturing engineering, process engineering, or advanced manufacturing experience.
• Experience within high-volume manufacturing environments.
• Demonstrated project management and technical leadership experience.
• Strong analytical and problem-solving capabilities.
• Excellent communication and interpersonal skills.

TECHNICAL COMPETENCIES:

REQUIRED:

• Powder metallurgy manufacturing processes.
• Material behavior of sintered metal.
• Precision grinding technologies.
• Abrasive machining and wheel optimization.
• Cutting and separation technologies.
• Surface finishing processes.
• Surface treatment and coating preparation methods.
• Dimensional metrology and inspection systems.
• Statistical Process Control (SPC).
• Process Capability Analysis (Cp/Cpk).
• Measurement System Analysis (MSA).
• Root Cause Analysis methodologies.
• Design of Experiments (DOE).
• Lean Manufacturing principles.

PREFERRED:

• Magnetic materials manufacturing.
• NdFeB, SmCo, Ferrite, or similar magnetic materials.
• Automated inspection and machine vision systems.
• Optical measurement systems.
• Industrial automation and robotics.
• PLC-controlled manufacturing equipment.
• ERP and Manufacturing Execution Systems (MES).
• Six Sigma Green Belt or Black Belt Certification.
• Minitab or equivalent statistical analysis software.
• Measurement System Analysis (MSA).
• Root Cause Analysis methodologies.
• Design of Experiments (DOE).
• Lean Manufacturing principles.

SPECIALIZED KNOWLEDGE – MECHANICAL PROCESSING:

THE IDEAL CANDIDATE POSESSES WORKING KNOWLEDGE IN:

• Precision grinding of brittle powder-metal and magnetic materials.
• Surface roughness control and finishing optimization.
• Geometric dimensioning and tolerance control.
• Grinding wheel selection, dressing, and process optimization.
• Cutting technologies for sintered and magnetic materials.
• Surface preparation and coating readiness.
• Optical and automated inspection systems.
• Vision-based quality control systems.
• Defect identification and classification methodologies.
• Yield improvement within finishing operations.
• Process validation and qualification methods.

LEADERSHIP COMEPETENCIES:

• Technical leadership without direct authority.
• Strong problem-solving and decision-making skills.
• Ability to lead cross-functional improvement projects.
• Effective communication at all organizational levels.
• Strong organizational and project management skills.
• Continuous improvement mindset.
• Ability to work within global and cross-functional teams.

KEY PERFORMANCE INDICATORS (KPIs)

• Process Capability (Cp/Cpk)
• First Pass Yield
• Scrap Reduction
• OEE Improvement
• Downtime Reduction
• Customer Complaint Reduction
• Cost Savings Achievement
• Successful New Process Implementation
• Safety Performance
• On-Time Completion of Improvement Projects

REQUIREMENTS:

Travel Requirements: 10% (as needed, domestic or international travel)

LANGUAGE SKILLS:

English, German beneficial

SUPERVISORY RESPONSIBILITIES:

No formal direct reports

EMPLOYMENT AT WILL:

This job description is intended as an outline of the duties of the position at VACUUMSCHMELZE and is subject to change by VAC from time to time. It is NOT a contract of employment. Employment at VAC is voluntarily entered into and is subject to termination by you or VAC AT WILL, with or without cause at any time, either party believes such action to be appropriate.