Steelmaking Process Optimization Engineer (Melt Shop)

Gerdau Steel - USA; Petersburg (VA); On-site; USD 105,000 - 121,000; Full time

Benefits offered by this job

Medical, Dental, Vision plans

401(k) match up to 6%

Tuition Reimbursement

Structured Career Path

Job summary

Gerdau Steel - USA in the Greater Richmond Region, VA seeks an engineer who turns data into safer, faster, cleaner melt shop operations. You will lead targeted continuous improvement initiatives to elevate melt shop safety, quality, reliability, and cost performance, and analyze production data to spot trends, quantify opportunities, and eliminate recurring issues.

Apply Lean, Six Sigma, and root cause analysis; plan, coordinate, and execute CAPEX projects from scoping through start-up; train

Qualifications

• 3–5 years of relevant experience in heavy industrial or process manufacturing.
• Experience leading CI and process optimization projects.
• Proven CAPEX planning/support experience.
• Knowledge of Lean Manufacturing and Six Sigma tools.
• Strong communication, coaching and cross-functional collaboration.

Responsibilities

• Lead continuous improvement initiatives to elevate safety, quality, reliability, and cost performance.
• Analyze production data to spot trends, quantify opportunities, and eliminate recurring issues.
• Apply Lean, Six Sigma and root cause analysis to reduce process variation.
• Plan, coordinate, and execute CAPEX projects from scoping through start-up.
• Train and coach teams in Lean tools and problem-solving techniques.
• Collaborate with production, maintenance, and leadership to optimize equipment and processes.

Skills

Lean Manufacturing

Six Sigma

Data analysis

CAPEX planning

Process optimization

Root cause analysis

Education

Bachelor’s in Engineering

Bachelor’s in Business Administration

Bachelor’s in Materials Science

High School Diploma/GED

Tools

SAP

Ishikawa Diagram

Job description

Are you the engineer who turns data into safer, faster, cleaner melt shop operations?Where you’ll work: Greater Richmond Region, south-central VirginiaRelocation: U.S. relocation support availablePay: $105,000–$121,000 base + Annual BonusWhy Gerdau?Up to 96% of our North American steel is made from recycled scrap—leading the way on sustainability and low embodied carbon.Financially strong, dividend-paying NYSE-listed company.Global scale, local impact, and a team-first culture focused on safety and innovation.What you’ll tackleLead targeted continuous improvement initiatives to elevate melt shop safety, quality, reliability, and cost performance.Analyze production/process data to spot trends, quantify opportunities, and eliminate recurring issues.Cut process variation using Lean, Six Sigma, and structured root cause analysis.Build and sustain process standards, systems, and best practices.Plan, coordinate, and execute CAPEX projects from scoping through start-up.Partner with production, maintenance, and leadership to optimize equipment and processes across the plant.Deliver training on continuous improvement tools and problem-solving techniques.Coach teams in Lean Manufacturing, Six Sigma, QIS, and Failure Analysis.Contribute to annual business planning, goal deployment, and strategic improvement roadmaps.Serve as a technical resource for process optimization and performance improvement.Advance a culture of safety and environmental compliance.Do you have what it takes?Degree: Bachelor’s in Engineering, Business Administration, Materials Science, or related field with 3–5 years of relevant experience; OR High School Diploma/GED with 6–8 years’ relevant experience.Industry: Heavy industrial or process manufacturing experience with knowledge of standardization and production quality methods.Plus: Steelmaking and melt shop background preferred; experience in scrap processing, melting, casting, rolling, maintenance, or finishing.Proven: Track record leading CI and process optimization projects; CAPEX planning/support experience.Toolbox: Lean Manufacturing, Six Sigma, root cause analysis, and quality improvement methodologies.Influence: Strong communication, presentation, coaching, and leadership skills with cross-functional partners.Tools and methods you’ll useData Analysis and ManipulationContinuous ImprovementTroubleshooting SkillsFishbone Diagram (Ishikawa Diagram)Process EngineeringProduction OptimizationLean Manufacturing PrinciplesSix Sigma ExperienceInvestment Casting (Foundry Operations)Process DevelopmentCAPEXOperational reliabilityRoot causeSystems you’ll touchSAPBenefits you can count on (Day 1 eligibility for medical/dental/vision)Comprehensive Medical, Prescription, Dental, and Vision plansHealth & Dependent Care Flexible Spending Accounts100% 401(k) match up to 6%Life/AD&D Insurance, Short-Term and Long-Term DisabilityPaid Parental LeaveHealth Advocate Services and an Employee Assistance ProgramTuition ReimbursementStructured Career Path and TrainingAn empowering, open culture with room to grow and createMake your markApply if you’re ready to lead change, solve complex challenges, and help shape the future of steel manufacturing.