Senior Consultant / Project Lead - Torque Expert

Job Description

Job Description

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’s primary customers are large automotive OEM, Tier 1 & 2 suppliers, and other plants within the manufacturing industry. To our clients, VSE provides practical, data-driven guidance and coaching that enhances plant performance. VSE was founded on a simple premise provide highly skilled and experienced consultants to support and generate significant value to our customers.  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 / Project Lead – Torque Expert is a technical leader responsible for providing guidance and process direction to plant and corporate staff members to optimize torque systems and improve quality performance within automotive assembly operations. This role focuses on ensuring design and process compliance for safety and critical joints, achieved through proper tooling parameters, control plans, adherence to standards, and effective risk management. The 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 torque performance within the assembly operation, while acting as the torque 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 torque 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 torque 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 joints, helping plant torque teams and leadership identify, prioritize, and track underperforming joints requiring improvement or corrective action.
• Assist and support the corporate Torque 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 fastening stations, evaluate process and control compliance, and identify weaknesses or non-conformances. Review torque 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 :

Position Qualifications :

Required :

Preferred :