Melt Shop Continuous Improvement Engineer

100Hires, Inc.; Petersburg (VA); On-site; USD 105,000 - 121,000; Full time

Benefits offered by this job

Comprehensive benefits day one

401(k) with 6% match up to 6%

Tuition reimbursement

Parental leave

Job summary

Gerdau, a global steel leader in the Greater Richmond Region, seeks a Lead Operational Excellence professional to drive continuous improvement in melt shop operations. You will apply data-driven methods to improve safety, quality, throughput, cost, and reliability.

You will mine production data, lead Lean, Six Sigma, and root-cause initiatives, plan CAPEX projects, and coach cross-functional teams toward standardized processes while maintaining a strong safety and environmental focus.

Qualifications

• Bachelor’s degree in Engineering, Business Administration, Materials Science, or related field with 3–5 years’ relevant experience; OR HS Diploma/GED with 6–8 years’ relevant experience.
• Experience in heavy industrial or process manufacturing; knowledge of standardization and production quality methods.

Responsibilities

• Own and deliver CI projects that elevate melt shop performance—safety, quality, throughput, cost, and reliability.
• Mine production/process data to uncover trends, opportunities, and recurring issues; drive corrective action using data-driven problem solving.
• Reduce variability and improve operational reliability through Lean, Six Sigma, and structured root cause methods.
• Create, roll out, and sustain process standards, best practices, and systems.
• Plan and execute CAPEX initiatives; manage scope, timelines, and stakeholder engagement.
• Partner with production, maintenance, and leadership to optimize equipment, processes, and plant performance.
• Facilitate training in continuous improvement and problem-solving techniques.
• Coach teams on Lean Manufacturing, Six Sigma, QIS, Failure Analysis, and related toolsets.
• Support annual planning, goal setting, and site-wide strategic improvements.
• Serve as a technical consultant to operations on process optimization and performance improvement.
• Champion a strong safety culture and environmental compliance every step of the way.

Skills

Data analysis

Continuous improvement

Lean manufacturing

Six Sigma

Root cause analysis

Problem solving

Process optimization

CAPEX

Education

Bachelor’s degree in Engineering, Business Administration, Materials Science, or related field

High School Diploma/GED with 6–8 years of relevant experience

Tools

SAP

Job description

Lead Operational Excellence in SteelmakingLocation: Greater Richmond Region, south-central VirginiaRelocation: Available within the U.S.Compensation: $105,000–$121,000 base salary + Annual BonusAbout GerdauGerdau is a global steel leader and a stable, dividend-paying company listed on the NYSE. Sustainability is in our DNA—up to 96% of our North American steel is produced from recycled scrap, and we deliver some of the lowest embodied carbon steel in the U.S.A Day in the LifeMorning starts with a safety huddle on the melt shop floor. You walk the line with production and maintenance leaders, using fresh process data to pinpoint reliability risks. By mid-morning, you’re mapping a root cause on a fishbone diagram and updating standard work. After lunch, you’re reviewing CAPEX timelines with project stakeholders, then coaching a cross-functional team through a Lean kaizen to reduce variation. You end the day aligning KPIs with plant leadership for the next improvement sprint.What You’ll DoOwn and deliver CI projects that elevate melt shop performance—safety, quality, throughput, cost, and reliability.Mine production/process data to uncover trends, opportunities, and recurring issues; drive corrective action using data-driven problem solving.Reduce variability and improve operational reliability through Lean, Six Sigma, and structured root cause methods.Create, roll out, and sustain process standards, best practices, and systems.Plan and execute CAPEX initiatives; manage scope, timelines, and stakeholder engagement.Partner with production, maintenance, and leadership to optimize equipment, processes, and plant performance.Facilitate training in continuous improvement and problem-solving techniques.Coach teams on Lean Manufacturing, Six Sigma, QIS, Failure Analysis, and related toolsets.Support annual planning, goal setting, and site-wide strategic improvements.Serve as a technical consultant to operations on process optimization and performance improvement.Champion a strong safety culture and environmental compliance every step of the way.What You BringBachelor’s degree in Engineering, Business Administration, Materials Science, or related field with 3–5 years’ relevant experience; OR High School Diploma/GED with 6–8 years’ relevant experience.Background in heavy industrial or process manufacturing; knowledge of standardization and production quality methods.Steelmaking/melt shop expertise preferred; experience in scrap processing, melting, casting, rolling, maintenance, finishing, or similar operations.Track record leading continuous improvement and process optimization.Experience planning or supporting CAPEX projects.Fluency in Lean Manufacturing, Six Sigma, root cause analysis, and quality improvement approaches.Clear communicator, strong presenter, capable coach, and influential leader across all levels.Skills & ToolsData Analysis and ManipulationContinuous ImprovementTroubleshooting SkillsFishbone Diagram (Ishikawa Diagram)Process EngineeringProduction OptimizationLean Manufacturing PrinciplesSix Sigma ExperienceInvestment Casting (Foundry Operations)Process DevelopmentCAPEXOperational reliabilityRoot causeSystems You’ll UseSAPBenefits That Start Day OneComprehensive Medical, Prescription, Dental, and Vision coverage (eligible on your first day)Health & Dependent Care Flexible Spending Accounts100% 401(k) match up to 6%Life and Accidental Death Insurance, STD, LTDPaid Parental LeaveHealth Advocate Services and Employee Assistance ProgramTuition Reimbursement ProgramCareer Path system with robust trainingAn open, empowering culture with room to grow and createReady to Build What’s Next?If you’re eager to lead change, solve complex problems, and shape the future of steel manufacturing, we want to hear from you.