Process Improvement Engineer - Melt Shop Operations

**Located in Greater Richmond Region of south-central Virginia / Relocation Available within the U.S. /Salary: $105,000-$121,000 + Annual Bonus **

Driven by sustainability, Gerdau produces up to 96% of its North American steel from recycled scrap. We pair this environmental focus with financial strength, standing as a highly stable, dividend-paying company on the NYSE.

Your Mission

As a key member of the operations team, you will partner with production leaders, maintenance teams, and plant management to improve safety, quality, productivity, reliability, and cost performance. You will serve as a change agent, helping implement best practices, standardization, and continuous improvement methodologies that support operational excellence.

Why Gerdau?

You will have the opportunity to drive meaningful improvements in a world-class manufacturing environment while building your career with a global leader with the lowest embodied carbon steel in the U.S. We value innovation, teamwork, safety, and continuous development, and we're looking for professionals who are passionate about making a lasting impact.

We Offer:

Comprehensive Medical, Prescription, Dental,Vision Plans – Eligible upon 1stday of hire
Health & Dependent Care (Flexible Spending Account)
100% Matching 401K up to 6%
Life/Accidental Life Insurance/STD/LTD
Paid Parental Leave
Health Advocate Services
Employee Assistance Program
Tuition Reimbursement Program
Career Path System and Training
An empowering and open culture with the opportunity to grow and create

Key Responsibilities:

Lead continuous improvement projects focused on Melt Shop operations and performance.
Analyze production and process data to identify trends, opportunities, and root causes of recurring issues.
Reduce process variation and improve operational reliability through data-driven problem solving.
Develop, implement, and maintain process standards, systems, and best practices.
Manage and support CAPEX projects from planning through execution.
Collaborate with production, maintenance, and leadership teams to improve equipment, processes, and overall plant performance.
Facilitate employee training on continuous improvement methodologies and problem-solving techniques.
Coach and develop employees on Lean Manufacturing, Six Sigma, QIS, Failure Analysis, and other improvement tools.
Support annual business planning, goal development, and strategic improvement initiatives.
Provide technical expertise and consulting to operations teams on process optimization and performance improvement.
Promote and support a strong culture of safety, environmental compliance, and operational excellence.

Qualifications Required:

Bachelor's degree in Engineering, Business Administration, Materials Science, or a related field with 3-5 years of relevant experience, OR a High School Diploma/GED with 6-8 years of relevant experience. Experience in heavy industrial, or process manufacturing environments.Knowledge of standardization and production quality methods required.
Strong knowledge of steelmaking and Melt Shop operations preferred.
Experience in scrap processing, melting, casting, rolling, maintenance, finishing, or related manufacturing operations.
Proven success leading continuous improvement and process optimization initiatives.
Experience managing or supporting CAPEX projects.
Knowledge of Lean Manufacturing, Six Sigma, root cause analysis, and quality improvement methodologies.
Strong communication, presentation, coaching, and leadership skills.
Ability to influence change and collaborate effectively across all levels of the organization.

Apply today if you are ready to lead change, solve complex challenges, and help shape the future of steel manufacturing.

You should be proficient in:

Data Analysis and Manipulation
Continuous Improvement
Troubleshooting Skills
Fishbone Diagram (Ishikawa Diagram)
Process Engineering
Production Optimization
Lean Manufacturing Principles
Six Sigma Experience
Investment Casting (Foundry Operations)
Process Development
CAPEX
operational reliability
root cause

Machines & technologies you'll use:

SAP