Design to Value (DTV) / Cost Engineering Consultant

About the role

A global consulting firm is supporting a consumer electricals manufacturer on a margin improvement programme covering direct materials, manufacturing and indirect costs. The client makes and sources fans, water heaters, lighting and other household appliances, using both in-house facilities and contract manufacturers. As part of the Design to Value (DTV) workstream, the consultant identifies and implements product-level cost optimisation opportunities across priority SKUs, working with R&D, quality, sourcing and manufacturing teams.

Key responsibilities

• Conduct product teardowns of client and competitor SKUs with the teardown partner, developing component-level Bills of Materials (BOMs), specifications and cost benchmarks.
• Build should-cost models for key components such as motors, blades, castings, sheet metal, PCBs, LED drivers, moulded plastics and packaging.
• Identify and evaluate DTV opportunities through material substitution, specification rationalisation, component and platform standardisation and packaging optimisation.
• Collaborate with R&D, quality and sourcing teams to check feasibility and ensure changes meet BEE, BIS and product reliability requirements.
• Support supplier discussions, prototype samples and manufacturing trials, tracking initiatives from validation and sign-off through implementation.
• Work hands-on with plant teams and R&D labs, maintaining cost models and tracking realised savings through the programme value tracker.

Required profile

• 5-8 years in product design, R&D, value engineering (VAVE) or cost engineering within consumer durables, FMEG or appliance OEM/ODM environments.
• Hands-on experience with fans, water heaters, lighting, kitchen appliances, air coolers or similar products; experience with leading consumer durables companies preferred.
• Bachelor's or master's degree in mechanical, electrical or electronics engineering.
• Track record of taking DTV/VAVE initiatives beyond ideation through validation and implementation.

Required skills

• Product teardowns, BOM costing, should-cost modelling and cost reduction identification.
• Practical knowledge of motors, sheet metal fabrication, die-casting, injection moulding and power electronics (LED drivers, BLDC controllers).
• Strong Excel-based cost modelling; ability to read engineering drawings preferred.
• Comfortable working cross-functionally and hands-on in manufacturing plants and R&D labs.