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Process Engineer - Melt Shop

Date: Nov 20, 2021

Location: Petersburg, VA, US, 23803

Company: Gerdau

About Us:

Gerdau Long Steel North America is a leader in mini-mill steel production and steel recycling in North America, with an annual manufacturing capacity of approximately 10 million metric tons of mill finished steel products. Through a vertically integrated network of mini-mills, scrap recycling facilities and downstream operations, the company serve customers throughout the U.S. and Canada, offering a diverse and balanced product mix of merchant steel, rebar, structural shapes, fabricated steel, flat-rolled steel, and wire rod. Steel is the material of choice for many elements of manufacturing, construction, transportation, and other consumer products. It is vital to our economic competitiveness and national security.


We Have: 

  • A strong global presence with mini-mills that transform millions of metric tons of raw material to produce steel beams, flat-rolled steel, merchant bar, rebar, spikes, and wire used by the automotive industry, appliance, construction, machinery, and equipment industries.    
  • A culture that welcomes diversity, encourages innovation and creates products that serve humanity.  
  • An environment that values teamwork, safety, and sustainability. 
  • A commitment to continuous improvement and the belief that we can create a better future for our employees and our global community by investing in people, processes, and technology. 


We Offer:

  • Comprehensive Medical, Prescription, Dental, Vision Plans – Eligible upon 1st day of hire 
  • Health & Dependent Care (Flexible Spending Account) 
  • 100% Matching 401K up to 6% 
  • Life/Accidental Life Insurance 
  • Bonuses 
  • 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 


You Have:

  • Bachelor’s degree in Mechanical or Electrical Engineering preferred, equivalent experience will be considered.  
  • 2 years minimum (5+ preferred) in a heavy industrial maintenance position.
  • Must have a working knowledge of manufacturing methods and techniques involving the use of mill machinery and related equipment, preferably in a steel making environment.
  • Must have the ability to manage multiple improvement initiatives in the maintenance areas (Project Management or Agile Development a plus).
  • Ability to train people and serve as a coach to employees that are not direct reports. The incumbent should possess solid presentation abilities combined with good interpersonal and organizational skills.
  • Must possess good communication skills, have the ability to articulate ideas, give feedback, resolve conflicts, and point out areas where improvement is needed, as well as the ability to develop a positive relationship with employees in order to develop credibility.
  • Must be results-oriented and have the ability to motivate others.


Your Purpose:

You will assist the site Improvement Facilitators, Routine Facilitators, department superintendents, and plant management in ensuring the efficiency and effectiveness of all improvement aspects within their area of responsibility. The major role of this job is to focus on continuous improvement and integration of improvement principles, technical and engineering principles, identifying best practices, consistent application of the Gerdau Business Systems, and act as a change agent to help achieve a higher level of results within the assigned location by utilizing and implementing improvement processes.  You will work in a steel manufacturing maintenance improvement capacity with no direct reports.


Your Work:

  • Develop, implement, and coordinate new as well as adjusting existing standards, structures, systems, and equipment in the Melt Shop department.
  • Ensure the efficiency and effectiveness of all improvement aspects and reaching improvement through the application of the available methods and tools provided through Gerdau's Business Systems and improvement principles in conjunction with the use of technical and engineering principles.
  • Assist management with the Annual Action Plan and the administration of established policies, procedures, and processes.
  • Provide oversight, contributions, and support of standardization processes, 5S initiatives, failure analysis, results-oriented management, and other process improvement methodologies. 
  • Strategize on maintenance, work instruction and methods.
  • Establish maintenance strategies to install and commission equipment.
  • Create plant preventative maintenance procedures.
  • Plan routine maintenance of plant equipment and machinery.
  • Analyze breakdowns, diagnose faults and supervise time critical equipment repairs.
  • Offer technical expertise to maintenance people like supervisor, foreman, fitters and technicians.
  • Function as project development member to maintain new equipment.
  • Work with reliability engineers to extend equipment life cycle.
  • Oversee and control maintenance costs.
  • Manage budget for current and future equipment upgrades and replacements.
  • Schedule and obtain project material and manpower.
  • Check work-in-progress and during completion to meet specifications.
  • Estimate costs on equipment, systems and structures repair or replacement.
  • Support ongoing preventative maintenance program.



Nearest Major Market: Richmond