Senior Consultant / Project Lead - Assembly Process Improvement

Job Description Job Description Company Overview: VSE Consulting Group, LLC VSE Consulting Group, LLC ("VSE") is a management consulting company focused on providing consulting services for Lean Manufacturing, quality improvement, and business & technology development. To our clients, VSE provides practical, data-driven guidance and coaching that enhances plant performance. We partner with the customer's organization to drive process improvement, develop employees' skills, and transfer knowledge, to achieve and sustain customer goals. VSE Consulting Group, LLC ("VSE") is seeking highly skilled and dedicated individuals to join our team and support our clients improve quality at their assembly plants. VSE's success has been driven by leveraging experienced, and talented consultants to deliver outstanding services to our manufacturing clients. Position Summary: The Senior Consultant is a technical leader responsible for providing guidance and process direction to plant and corporate staff members to optimize assembly systems and improve quality performance within automotive assembly operations. This role focuses on ensuring design and process compliance for safety and critical processes, achieved through proper tooling parameters, control plans, adherence to standards, and effective risk management. The Sr. Consultant facilitates the use of advanced problem-solving methods, provides guidance on root cause analysis, and drives plant staff to implement robust containment, corrective, and preventive actions. The goal is to achieve sustainable improvements in torque system performance, product quality, and plant KPIs. Key Responsibilities: * Serve as the consulting project lead supporting the plant in improving performance within the assembly operation, while acting as the processes/systems subject matter expert (SME) for both the customer and VSE. * Lead structured problem-solving activities (Shainin, Kaizen, Six Sigma DMAIC, 8D) to address chronic and systemic issues creating torque failures driven by multiple root causes (4M1D: Man, Method, Machine, Material, Design). * Conduct and facilitate risk assessments for station and tooling risks (i.e., PFMEA, DFMEA, Station Risk Assessment) to ensure effective risk identification, prioritization, and mitigation. * Perform and analyze CP/CPK capability studies to assess process stability, prioritize improvement areas, and verify corrective actions. Categorize results into performance intervals to determine priority levels for improvement. * Develop and maintain tracking charts or scorecards (C/1000 defect-rate performance) to enable visual monitoring of all safety and critical processes, helping plant plant teams and leadership identify, prioritize, and track underperforming joints requiring improvement or corrective action. * Assist and support the corporate / plant Team in developing live dashboards for critical data such as C/1000 performance and CP/CPK metrics (from Atlas Copco or equivalent systems), enabling real-time monitoring, performance evaluation, and data-driven improvement actions. * Lead and participate in GEMBAs (Critical Process Reviews) to observe stations, evaluate process and control compliance, and identify weaknesses or nonconformance's. Review stations not meeting standards, document findings, and coordinate containment, corrective, and preventive actions with Engineering, Maintenance, and Quality to drive closure and sustain improvements. * Based on GEMBA findings: Assess tooling for compliance to standards (Basic Conditions), verify controller setup and tooling parameter settings, and verify or confirm tooling function and proper performance of error-proofing. Understand potential risks associated with torque failures, defects being created, and released from the station. * Drive continuous improvement initiatives to enhance First Time Capability (FTC), Second Time Capability (STC), and reduce repair inventory and torque-related rework. * Support Series Production (carryover) plants with containment, corrective, and preventive actions, and support new vehicle launches and mid-cycle actions (MCAs) through proactive risk assessments and process validation. * Provide coaching and mentorship in Advanced Problem Solving, PFMEA, SPC, and process control disciplines to develop internal plant capability. * Deliver clear, data-driven weekly progress reports summarizing systemic issues, corrective actions, and measurable improvements. Expected Outcomes: * Reduce defects and improve process capability through structured problem solving, analysis, robust controls, and corrective actions. * Improve assembly plant key performance indicators (KPIs), including First Time Capability (FTC), Second Time Capability (STC), and vehicle throughput. * Address top issues and reoccurring issues that result in online failures, production losses, and vehicles requiring offline repair. * Demonstrate measurable improvements in process performance, systemic issue resolution, and increases in throughput by improving process capability and reducing failures. * Provide our customers with sustainable gains by supporting their staff members (corporate and plant) with guidance, knowledge transfer, capability building, and exposure to industry best practices. Position Qualifications - Required: * Bachelor's degree or higher in Mechanical Engineering, Electrical Engineering, or a Technical Discipline (equivalent experience may be considered). * Minimum of 20 years supporting automotive assembly plants with on-site experience. * Expertise in torque systems and related advanced problem-solving activities. * Experience applying advanced problem-solving methodologies such as Lean Manufacturing, Six Sigma, Shainin, or equivalent methods. * Experience conducting PFMEAs or station risk assessments for assembly stations performing operations on safety or critical processes. * Demonstrated experience improving assembly processes, quality metrics, and process capability. * Experienced and comfortable working with data to identify trends, validate process capability, and support root-cause analysis. * Self-motivated and able to work effectively in high-intensity environments managing multiple priorities and plant activities. * Strong communication skills (written and verbal). * Fluent in English - written and verbal. * Proficient in Microsoft 365 applications (Excel, PowerPoint, Word, Teams). Position Qualifications - Preferred: * 20 years of experience in manufacturing, quality, or assembly operations within OEM or Tier 1 environments. * Prior OEM product engineering, manufacturing engineering, and/or new launch experience. * Extensive experience performing PFMEA, DFMEA, and other risk assessment methodologies. * Proven ability to develop others through coaching, mentoring, and structured training in problem-solving methodologies. * Strong leadership presence with the ability to engage both plant management and hourly personnel. VSE is an Equal Opportunity Company: Race, Color, Religion, Sex, Sexual Orientation, Gender Identity, National Origin, Age, Genetic Information, Disability, Protected Veteran Status, or any other legally protected group status.