Consultant Process Improvement

VSE CONSULTING GROUP LLC•Peoria, IL

7d•Onsite

About The Position

VSE Consulting Group LLC provides practical, data-driven consulting in lean manufacturing, quality improvement, launch readiness, and business and technology development. We work alongside automotive manufacturers and suppliers to strengthen plant performance, develop employee capability, transfer knowledge, and sustain measurable results. The Consultant - Process Improvement provides hands-on technical support for an automotive torque process improvement engagement. Working with the Project Lead and plant teams, this role assesses fastening processes, analyzes torque and equipment data, validates joint and tool capability, implements corrective actions, and helps establish the daily controls needed to reduce defects, downtime, rework, and recurring failures.

Requirements

Bachelor's degree or technical credential in Mechanical, Electrical, Manufacturing, Industrial, Quality, or a related discipline; directly relevant automotive manufacturing experience may be considered in place of a degree.
At least 5 years of automotive assembly, manufacturing engineering, quality, maintenance, launch, or related plant experience with meaningful hands-on process-improvement responsibility.
Working knowledge of powered fastening tools, controllers, joint behavior, torque strategies, parameter development, process control, and troubleshooting.
Experience with PFMEA, control plans, SPC, capability analysis, measurement systems, calibration, process audits, error proofing, and structured root-cause analysis.
Ability to interpret drawings, specifications, joint requirements, torque curves, controller data, process information, and equipment documentation.
Strong data-analysis and reporting skills using Microsoft Excel and PowerPoint; experience with Minitab, Power BI, or comparable tools is beneficial.
Clear written and verbal communication, disciplined action follow-up, and the ability to work effectively with engineers, skilled trades, production, quality, suppliers, and customer leaders.
Willingness to work flexible or off-shift plant hours and travel regularly to customer sites in the United States, Canada, and Mexico.

Nice To Haves

Hands-on experience with Atlas Copco, Cleco, Desoutter, Stanley, or comparable fastening platforms and related data systems.
Experience supporting vehicle launches, PPAP, run at rate, safe launch, production ramp-up, or high-volume assembly troubleshooting.
Formal training in Six Sigma, Lean Manufacturing, Shainin, quality auditing, or project management.
Experience creating dashboards, automating data analysis, documenting financial benefits, or training local technical resources.

Responsibilities

Perform plant-floor assessments of torque joints, fastening tools, controllers, sockets, spindles, fixtures, traceability interfaces, repair processes, standard work, and backup-tool readiness.
Support deployment of the torque operating system, RASCI ownership, technical standards, monitoring routines, audits, reaction plans, escalation paths, and required documentation.
Develop and validate torque parameters using engineering requirements, joint behavior, rundown studies, torque curves, controller results, correlation checks, and production evidence.
Conduct tool and joint capability studies using measurement system principles, Cp, Cpk, Pp, Ppk, control charts, sampling plans, and agreed acceptance criteria.
Support process readiness and launch activities, including PFMEA and control-plan alignment, calibration, trials, PPAP, run at rate, safe launch, ramp-up, and closure of open technical risks.
Execute daily monitoring, GEMBAs, critical-process reviews, layered process audits, and torque-station audits; verify preventive maintenance, calibration, parameter control, error proofing, and standardized work.
Respond to quality or equipment abnormalities by escalating issues, supporting suspect-product containment and segregation, troubleshooting equipment and process conditions, and verifying repair or release evidence.
Analyze torque curves, fault codes, repair records, downtime, defect and rework trends, and process observations to identify root causes across people, equipment, material, method, measurement, and design factors.
Implement and verify corrective actions that improve first-time capability, throughput, tool availability, and production stability while reducing defects, offline repair, repeat failures, and warranty exposure.
Validate assigned hot, portable, or multi-joint backup tools, including configuration, storage, readiness checks, activation, parameter control, response time, and return-to-service requirements.
Maintain dashboards, Pareto and trend views, action registers, benefit calculations, and closure evidence supporting project KPIs and the team's approximately $600,000 quality and cost improvement objective.
Create practical standard work and training materials, coach customer and local resources, document technical learning, and demonstrate process ownership to support long-term sustainment near the Rivian facility.
Follow all customer safety, environmental, security, confidentiality, and information-handling requirements, and stop or escalate work whenever product or personnel safety is at risk.