Staff Maintenance / Reliability Engineer

The posting, as Vulcan Elements wrote it

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 Integrity.

As our Staff Maintenance / Reliability Engineer you will support equipment design, installation, commissioning, and startup while developing maintenance strategies and technical standards that sustain safe, reliable production. Core responsibilities include detailed equipment failure analysis, materials of construction evaluations, engineered seal and gasket selection, and development of preventive and predictive maintenance programs. The role will also help build the site's CMMS, translating OEM requirements and operating experience into accurate asset data and executable maintenance plans.

The ideal candidate combines sound engineering judgment with practical experience troubleshooting complex industrial equipment. They will work directly with technicians, equipment vendors, R&D, Operations, and Engineering to resolve technical problems, capture lessons from the pilot plant, and continuously improve equipment performance.

Responsibilities

• Lead detailed equipment and component failure investigations, including field inspection, teardown, operating-data review, materials evaluation, root cause determination, and verification of corrective actions.
• Identify and evaluate failure mechanisms such as fatigue, corrosion, erosion, abrasion, thermal degradation, chemical incompatibility, mechanical overstress, and premature component wear.
• Apply equipment criticality assessments, FMEA, and reliability-centered maintenance principles to identify risks, prioritize improvements, and define appropriate maintenance strategies.
• Analyze downtime, repeat failures, MTBF, MTTR, and maintenance history to establish reliability priorities and measure the effectiveness of engineered solutions.
• Engage OEMs, component suppliers, and technical laboratories as needed to validate failure mechanisms, specify design improvements, and prevent recurrence.
• Evaluate and recommend materials of construction for equipment components based on temperature, pressure, vacuum service, process chemistry, corrosion, erosion, wear, and mechanical loading.
• Develop component-selection and replacement strategies for gaskets, O-rings, mechanical seals, packing, and other sealing systems, considering chemical compatibility, thermal cycling, leakage risk, operating life, and serviceability.
• Investigate seal and gasket failures, including compression set, chemical attack, extrusion, thermal aging, installation damage, and sealing-surface deterioration; translate findings into improved specifications and maintenance practices.
• Work with Engineering, OEMs, and Procurement to

[…]
Demonstrated experience conducting detailed equipment failure investigations and implementing sustainable engineering solutions to recurring reliability problems.

• Practical knowledge of materials compatibility, industrial seals and gaskets, common component degradation mechanisms, and appropriate material selection for process service.
• Experience developing preventive maintenance content, equipment asset data, technical documentation, and CMMS maintenance plans, with strong field troubleshooting and cross-functional communication skills.
• Working knowledge of industrial maintenance safety, including LOTO, stored-energy hazards, and safe work practices around complex industrial equipment.

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

Preferred Qualifications

• Experience supporting pilot plants, greenfield facilities, major equipment installation, commissioning, or production ramp-up.
• Background in metals processing, chemical manufacturing, advanced materials, automotive, or other equipment-intensive manufacturing; experience with furnaces, vacuum systems, powder handling, or precision machinery is particularly relevant.
• Familiarity with RCM, condition monitoring, mechanical integrity programs, and reliability certifications such as CMRP or CRE.

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.