Consultant - Electrical Process Improvement in Wayne
Listed on 2026-05-14
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Engineering
Quality Engineering, Manufacturing Engineer, Electrical Engineering, Process Engineer
Company Overview:
VSE Consulting Group, LLC ("VSE") is a management consulting company focused on providing consulting services for Lean Manufacturing, quality improvement, and business & technology development. 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.
Job Summary:The Consultant – Electrical Process Improvement is a technical expert in electrical systems, testing and assembly process. Main responsibilities will be supporting the VSE Project Lead at the customer’s site by driving activities to improve plant electrical performance and addressing top problems impacting assembly plants. This role focuses on ensuring process compliance for critical operations, assisting with capability studies (CP/CPK), C/1000 defect‑rate tracking, PFMEA support, and risk mitigation across assembly operations.
The consultant provides detailed technical analysis, supports GEMBA reviews, assists in electrical problem solving and contributes to corrective and preventive action implementation under guidance of VSE Project Lead and/or other senior consultants.
- Support the VSE Project Lead in all electrical-related improvement activities at the assembly plant, including issue identification, analysis, and corrective action tracking.
- Perform electrical data collection and analysis, including CP/CPK capability studies, identifying trends, and escalating process capability concerns.
- Assist in developing and maintaining C/1000 performance charts and visual scorecards to track the health of electrical process and critical stations and highlight problem areas.
- Participate in GEMBAs (Critical Process Reviews) and help document findings related to nonconformance, process deviation, or tooling performance.
- Support risk assessments (PFMEA, DFMEA, Station Risk Assessment) and ensure findings are documented and corrective actions are validated.
- Conduct process observations and electrical audits to verify adherence to control standards, tooling setup, and error-proofing functionality.
- Assist in troubleshooting electrical tools/equipment and parameter settings to ensure process capability and repeatability.
- Support the creation and maintenance of dashboards and reports for plant leadership to visualize electrical process performance.
- Collaborate with quality, maintenance, and manufacturing teams to validate corrective and preventive actions and drive sustainable improvements.
- Provide input to continuous improvement initiatives, focusing on improving First Time Capability (FTC), Second Time Capability (STC), and reducing rework due to electrical-related issues.
- Participate in knowledge sharing and training sessions led by the Project Lead to strengthen internal plant problem-solving capability.
- Improved electrical process capability and compliance to standards.
- Reduction in electrical-related defects, C/1000 failure rates, and rework at offline repair.
- Increased plant awareness and visibility of top systemic electrical issues and their resolution status.
- Measurable improvement in FTC, STC, and throughput metrics related to electrical operations.
- Enhanced collaboration and technical communication between electrical, Quality, and Production teams.
Required:
- Bachelor’s degree in Mechanical engineering, Electrical engineering, Industrial engineering, or related technical field.
- 10 years of experience in automotive assembly or manufacturing environments.
- Proficient in Microsoft Excel, Minitab, Power BI, and electrical systems.
- Knowledge of Lean Manufacturing and structured problem-solving methodologies (Shainin, Kaizen, Six Sigma, 8D, DMAIC).
- Working knowledge of PFMEA, DFMEA, Risk Assessment, control plans, and process audits.
- Strong analytical and data management skills; able to interpret CP/CPK data and defect trends.
- Self-motivated, disciplined, and detail-oriented with strong problem-solving drive and initiative.
- Effective communicator; able to collaborate across quality, maintenance, and production functions.
- Exposure to launch and mid-cycle actions (MCA) within OEM or Tier 1 assembly plants.
- Experience with proactive activities to ensure station setup, process readiness for new launches — driving station performance, process stability, and adherence to best practices.
VSE is an Equal Opportunity Company:
Race, Genetic Information, Protected Veteran Status, or any other legally protected group status.
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