Senior Consultant – VAVE Program

Senior Consultant – VAVE ProgramLocation: Cottage Grove, MN (Each location to be visited once. USA (CA, NE, ND, NC, OH) and Tijuana (Mexico). May add few more locations.)Onsite/Hybrid/Remote: HybridDuration: 3 MonthsRole 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 ResponsibilitiesVAVE Strategy, Planning AlignmentTranslate 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 PreparationReview 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 SessionsLead 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 DevelopmentGuide 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 impactsEnsure savings assumptions are realistic, evidence-backed, and auditable.Coordinate supplier's risk assessments (DFMEA/PFMEA updates).Validation Planning CoordinationWork 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 ManagementMaintain 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 HandoverEnsure 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 SkillsExperience: 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 RoleVAVE roadmap execution planBaseline cost analysis teardown insightsVAVE workshop outputs and idea funnelTechnical and commercial feasibility packsSavings validation documentsRisk register, validation planFinal VAVE report for client approvalImplementation readiness package