Consultant Program Manager Jobs in Hudson, WI (NOW HIRING)

Job Title: Senior Consultant – VAVE Program

Location: St. Paul, MN (Each location to be visited once. USA (CA, NE, ND, NC, OH) and Tijuana (Mexico). May add few more locations.)

Onsite/ Hybrid/ Remote: Hybrid

Duration: Fulltime / Contract

Job Summary:

• The Senior VAVE Consultant will lead, anchor, and execute the end‑to‑end VAVE program directly at the supplier’s facility for Industrial products.
• This role ensures that the supplier generates credible, feasible, and implementable cost‑reduction ideas without compromising quality, reliability, performance, or regulatory compliance.
• Consultant will work closely with the Program Manager, the client's cross-functional teams, and the supplier’s cross‑functional teams to ensure the program delivers validated savings.

Key Responsibilities

VAVE Strategy, Planning & Alignment

• Translate client expectations, product scope, and savings targets into a structured VAVE execution roadmap for the supplier.
• Establish clear governance, cadence, workshop plans, and decision gates for supplier‑side execution.
• Ensure supplier leadership and cross‑functional teams (Design, Manufacturing, Procurement, Quality etc.,) are aligned, resourced, and accountable.
• Define VAVE workstreams: material, design, process, standardization, and specification optimization.

Technical Analysis & Baseline Preparation

• Review supplier’s current product cost structure, BOM, routing, manufacturing processes, tooling.
• Perform structured analyses: functional analysis, cost driver mapping, tear‑down insights, benchmarking, alternate material/process feasibility.
• Identify major value levers and prioritize high‑impact VAVE zones.

Facilitation of Workshops & Ideation Sessions

• Lead and facilitate on‑site VAVE workshops using industry‑standard methods (FAST, DFMA, 7‑step VAVE, idea funneling etc.,).
• Drive supplier participation, ensuring ideas originate from their teams.
• Promote creative but practical ideation, leveraging benchmarks and cross‑industry best practices.
• Maintain a traceable idea register.

Technical & Cost Feasibility Development

• Guide supplier engineers in developing VAVE concepts to a technically defensible level.
• Review supplier calculations: BOM impact, Labor/cycle time changes, Tooling implications, Yield and scrap effects, Supply chain and logistics impacts
• Ensure savings assumptions are realistic, evidence‑backed, and auditable.
• Coordinate supplier’s risk assessments (DFMEA/PFMEA updates).

Validation Planning & Coordination

• Work with supplier teams to define prototype, test, and qualification needs for each shortlisted idea.
• Coordinate trials, PPAP/FAI readiness, and supplier internal testing.
• Ensure ideas meet client’s quality, regulatory, safety, and performance standards.

Reporting, Documentation & Stakeholder Management

• Maintain up‑to‑date documentation—idea funnel, business cases, risks, decisions, and validation progress.
• Provide weekly progress reports to the Program Manager with clear risks, dependencies, and decisions needed.
• Present VAVE outputs to client engineering, procurement, and leadership stakeholders.
• Drive alignment between supplier and client during reviews.

Implementation Readiness & Handover

• Ensure ideas approved by client are ready for implementation (complete drawings, process updates, validation evidence).
• Support supplier to prepare implementation timelines, investment requests, and transition plans.
• Ensure a clean handover into implementation tracking.

Required Skills & Experience

Experience

• 15+ years in VAVE/Value Engineering, NPD, Manufacturing Engineering, Cost Reduction, or Industrial Engineering.
• Proven experience leading VAVE programs at tier‑1 or tier‑2 suppliers in relevant industries (electro‑mechanical, industrial, automotive, electronics, consumer products, etc.).
• Strong background in product cost breakdown, design‑for‑manufacture/assembly, and manufacturing processes.

Technical Skills

• Deep understanding of BOM, cost modeling, manufacturing processes, tooling, materials, and supply chain economics.
• Skilled in structured VAVE tools and methodologies:  FAST diagrams, DFMA, Tear‑down/value analysis, Benchmarking, Cost driver modeling
• Ability to interpret drawings, specifications, engineering change documents.

Behavioral Skills

• Strong workshop facilitation and cross‑functional leadership.
• Excellent stakeholder management across supplier teams and client teams.
• Able to handle conflicts, push for accountability, and maintain neutrality.
• High clarity in communication, documentation, and presentations.

Typical Deliverables of this Role

• VAVE roadmap & execution plan
• Baseline cost analysis & teardown insights
• VAVE workshop outputs and idea funnel
• Technical and commercial feasibility packs
• Savings validation documents
• Risk register, validation plan
• Final VAVE report for client approval
• Implementation readiness package