Senior Product Cost Architect - Design-to-Cost Leader

JOB SUMMARY: The Senior Product Cost Engineer is responsible for developing and executing the product cost strategy for a next-generation commercial chassis platform from concept through production launch. This role owns engineering cost modeling, design-to-cost execution, value analysis/value engineering (VA/VE), design for manufacturing and assembly (DFM/DFA), and cost optimization across the complete vehicle. Working alongside Engineering, Manufacturing, Supply Chain, and Strategic Sourcing, this position ensures cost objectives are achieved without compromising safety, quality, reliability, manufacturability, or vehicle performance. This engineer will influence vehicle architecture, supplier selection, manufacturing processes, and engineering decisions by providing data-driven cost analyses, technical trade studies, and design recommendations throughout the product lifecycle. This is a high-impact role for an experienced engineer who thrives in ambiguity, challenges conventional thinking, and wants meaningful ownership over one of the primary drivers of program profitability and launch success.

ESSENTIAL DUTIES AND RESPONSIBILITIES: Product Cost Ownership: Own product cost development, tracking, and optimization across the complete commercial chassis platform from concept through production launch. Design-to-Cost Strategy: Establish and drive design-to-cost objectives by partnering with engineering teams to balance cost, performance, quality, manufacturability, durability, and customer requirements. Value Analysis / Value Engineering (VA/VE): Lead VA/VE activities to identify cost reduction opportunities through design optimization, material selection, process improvements, supplier innovation, and product simplification. Design for Manufacturing & Assembly (DFM/DFA): Drive DFM/DFA principles throughout product development to improve manufacturability, reduce assembly complexity, minimize labor content, and improve production efficiency. Cost Modeling & Trade Studies: Develop detailed component, subsystem, and vehicle-level cost models to support architecture decisions, supplier sourcing strategies, make-versus-buy analyses, and engineering trade-offs. Cross-Functional Cost Leadership: Partner with Engineering, Manufacturing, Strategic Sourcing, Supplier Development, Quality, Finance, and Program Management to ensure technical decisions support program cost objectives. Supplier Cost Collaboration: Work directly with suppliers to evaluate technical proposals, identify cost reduction opportunities, benchmark competitive solutions, and support commercial negotiations through engineering analysis. Product Change Cost Analysis: Evaluate engineering changes for piece cost, tooling investment, manufacturing impact, lifecycle cost, warranty exposure, and overall business case. Manufacturing & Launch Support: Support prototype builds, manufacturing launch, and early production by identifying cost optimization opportunities while maintaining production readiness and launch timing. Continuous Cost Improvement: Establish ongoing cost reduction roadmaps throughout product development and production while maintaining product performance, quality, and customer expectations. Operate in Ambiguity: Create structure and drive execution where product definitions, supplier strategies, manufacturing processes, and cost targets continue to evolve. Software Release Management: Manage calibration revisions, software releases, configuration control, and production-ready datasets supporting prototype, validation, manufacturing, and production programs. Compliance & Functional Performance: Ensure vehicle control strategies meet emissions, safety, diagnostics, cybersecurity, and applicable commercial vehicle regulatory requirements. Launch & Production Support: Support prototype builds, validation testing, manufacturing launch, and early production by rapidly resolving controls-related issues and optimizing vehicle performance. Operate in Ambiguity: Create structure and drive execution in environments where vehicle architectures, software, propulsion technologies, and performance requirements evolve simultaneously. KNOWLEDGE, SKILLS AND ABILITIES FOR SUCCESS Strong understanding of automotive or commercial vehicle product cost development and cost engineering methodologies Experience leading Design-to-Cost, VA/VE, DFM, and DFA initiatives Ability to evaluate engineering trade-offs involving cost, performance, quality, manufacturability, serviceability, and durability Experience developing component, subsystem, and vehicle-level cost models Strong understanding of manufacturing processes including fabrication, machining, casting, molding, welding, stamping, assembly, and automation Experience supporting supplier sourcing, quoting, should-cost analysis, and cost negotiations Strong analytical, financial, and engineering problem-solving capability Ability to influence technical decisions across engineering, manufacturing, supply chain, and supplier organizations without direct authority Strong communication, presentation, and decision-making skills BASIC EDUCATION AND EXPERIENCE REQUIRED Bachelor's degree in Electrical Engineering, Automotive Engineering, Aerospace Engineering, Mechatronics, Computer Engineering, or related engineering discipline 7+ years of experience in product cost engineering, manufacturing engineering, product development, value engineering, or commercial vehicle engineering All candidates must be a U.S. citizen or permanent resident. Candidates must be authorized to work in the United States and will be required to provide proof of employment eligibility at the time of hire. PREFERRED EXPERIENCE Demonstrated experience developing product cost strategies from concept through production launch Experience leading VA/VE, Design-to-Cost, DFM, and DFA activities on production vehicle programs Experience working cross-functionally with Engineering, Manufacturing, Supply Chain, Strategic Sourcing, Finance, and suppliers Experience supporting supplier technical reviews, should-cost analysis, or cost optimization initiatives Experience with commercial vehicles, body-on-chassis platforms, vocational vehicles, or heavy-duty vehicle programs Experience supporting clean-sheet vehicle development or major platform redesign programs Experience with supplier cost modeling, manufacturing cost analysis, and competitive benchmarking Experience supporting sourcing strategy, supplier negotiations, and industrialization activities Experience applying Lean Manufacturing, Six Sigma, or Advanced Product Quality Planning (APQP) methodologies Master's degree in Engineering, Manufacturing, Industrial Engineering, or Business Administration Experience supporting accelerated product launches in low-process or rapidly evolving engineering organizations WE'RE LOOKING FOR SOMEONE WHO Takes ownership of complex engineering cost challenges and drives them to resolution Thrives in fast-paced environments where product definition and priorities evolve rapidly Thinks at the complete vehicle level and understands how engineering decisions influence total product cost Challenges conventional approaches and identifies innovative opportunities to improve cost without sacrificing quality, reliability, or customer value Balances engineering excellence with manufacturing realities, supplier capabilities, launch timing, and business objectives Communicates effectively across engineering, manufacturing, supply chain, suppliers, and executive leadership Wants meaningful ownership over the engineering decisions that define the commercial success of a new vehicle platform INCLUDES Benefits including medical, dental and vision insurance, 14 paid holidays, vacation time and 401k matching WORK CONDITIONS The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. Office environment and production environment Must work in a manufacturing environment with exposure to heat, cold and noise Fast-paced production area with moving objects and sheet metal Occasional periods of standing or sitting for extended periods of time You must wear appropriate PPE when and where required Frequent weeks working 40+ hours Frequent communication with people throughout the day *The specific statements shown in each section of this description are not intended to be all-inclusive. They represent typical elements and criteria necessary to successfully perform the job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions Blue Bird is an equal opportunity employer and makes employment decisions on the basis of merit. We strive to have the best available talent in every job based on the Knowledge, Skills and Abilities each person brings. Blue Bird is committed to compliance with all applicable laws providing equal employment opportunities. This commitment applies to all persons involved in Company operations and prohibits unlawful discrimination in all forms. All candidates must be a U.S. citizen or permanent resident. Candidates must be authorized to work in the United States and will be required to provide proof of employment eligibility at the time of hire. LI-onsite

Qualifications: Education Required Bachelors or better in Electrical Engineering or related field.

Experience Required: 7 years: 7 years: Experience in product cost engineering, manufacturing engineering, product development, value engineering, or commercial vehicle engineering Equal Opportunity Employer This employer is required to notify all applicants of their rights pursuant to federal employment laws. For further information, please review the Know Your Rights notice from the Department of Labor.