Process Controls Engineer

Company Overview

FXI is a leading producer of foam innovation in Bedding, Furniture, Industrial, Home & Office, Healthcare, and Transportation markets. We have made it our mission to provide tailored solutions that delight our customers and consumers. With our corporate headquarters, high‑tech research and development facility, and multiple manufacturing locations in North America, FXI has built a culture of innovation and achievement that is recognized by customers, suppliers and peers.

Our products include finished goods, sub‑assemblies, services, and raw materials for OEMs, fabricators, and retailers. You will find FXI's foam innovations inside, around, and under yourself in countless applications. Everywhere foam goes, FXI's innovations lead the way! Won't you join us?

Our Fort Wayne facility is a union manufacturing plant with approximately 155 employees operating on three shifts. The site is a pouring and specialized post‑processing operation. Capabilities include pouring, fabricating, felting, reticulation (two styles) and block. As a key location within FXI’s manufacturing network, the Fort Wayne plant is known for its strong focus on quality, safety, and operational excellence. Team members work in a collaborative, supportive environment where continuous improvement and innovation play a central role.

The Process Controls Engineer is responsible for improving and maintaining process stability, consistency, and performance across manufacturing operations. This role focuses on monitoring, analyzing, and optimizing process variables (e.g., temperature, pressure, speed, thickness) through control strategies, data analysis, and automation improvements.

This position requires a strong presence on the production floor. The engineer must actively engage with operators, observe equipment and workflows in real time, and develop a deep understanding of the process. Success in this role depends on the ability to translate operator feedback and hands‑on observations into practical improvements that enhance safety, efficiency, and ease of operation.

The ideal candidate brings a positive, team‑oriented attitude and a strong work ethic, with the ability to collaborate effectively across operations, maintenance, and engineering teams to drive meaningful process improvements.

• Maintain an active presence on the production floor to observe processes, equipment behavior, and operator workflows in real time
• Engage directly with production associates to understand challenges, gather feedback, and identify opportunities for improvement
• Translate hands‑on observations and operator input into actionable process and control improvements
• Identify and implement solutions that improve operator safety, reduce complexity, and increase overall efficiency
• Build strong working relationships with operations by demonstrating responsiveness, respect, and a collaborative, team‑first mindset
• Develop, implement, and optimize control strategies to improve process stability and performance
• Tune and maintain PID control loops and advanced control schemes
• Analyze process data to identify sources of variation, inefficiency, and scrap
• Support troubleshooting of process‑related issues and drive root cause analysis
• Collaborate with operations, engineering, and maintenance on automation and instrumentation improvements
• Evaluate and implement upgrades to control systems (e.g., PLCs, HMIs, drives, sensors)
• Standardize process control methodologies and documentation
• Provide technical guidance and training to operators and technicians
• Provide design, cost estimation, and implementation of a wide variety of projects that are intended to expand manufacturing capabilities, improve manufacturing operations, quality, safety, and reduce costs of production
• Work with technical team to manage project design documentation including panel design drawings, bills of material, conduit and wiring schedules, point‑to‑point and I/O wiring diagrams and power distribution drawings
• Provide field supervision of in‑house personnel, outside contractors and integrators during design, implementation and commissioning phases of…