Manager, Scale-Up Engineer

FXI; Aston Township (PA); Hybrid; USD 110,000 - 160,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

Basic and optional life insurance

Short and longterm disability coverage

401(k) plan with company match

Tuition assistance

Flexible spending accounts

Job summary

FXI in Aston, PA is seeking a Manager of Scale-Up Engineering to bridge product development, engineering, and manufacturing. You will own the transition of new product concepts from prototypes and initial customer samples through successful, full-scale commercial production.

This role requires translating requirements into robust manufacturing solutions, ensuring manufacturability, and validating processes for ramp-ready production with hands‑on execution and cross‑functional collaboration.

Qualifications

• Bachelor's degree in Mechanical, Industrial, or Manufacturing Engineering.
• 3+ years of experience in process or scale‑up engineering with preference for polyurethane foam, bedding, or consumer goods manufacturing.
• Strong command of process development, validation, and scale‑up from pilot to full production.
• Working knowledge of process capability, statistical methods, and root‑cause problem solving (DOE, SPC, RCA & FMEA).
• Proven project management skills and ability to influence cross‑functional teams while managing multiple launches.
• Willingness to work hands‑on across R&D, pilot, and plant environments, including travel to manufacturing sites as needed.

Responsibilities

• Drive the scale‑up of new products and processes from design for manufacturability through validated, full‑scale commercial production.
• Translate development‑stage designs into robust, documented, repeatable manufacturing specifications.
• Support the handoff to operations with validated processes, training, and documentation for a successful launch.
• Partner with plant teams to install, start up, and troubleshoot new manufacturing processes, resolving issues that impact form, fit, or function during ramp.
• Identify and resolve scale‑up challenges early, ensuring products and processes are robust and production ready.

Skills

Process development

Validation

Scale-up

Design of Experiments

Statistical Process Control

Root Cause Analysis

FMEA

Project management

Cross-functional collaboration

Hands-on manufacturing

Education

Bachelor's degree in Mechanical Engineering OR Industrial Engineering OR Manufacturing Engineering

Job description

Job Title: Manager, Scale-Up Engineering

Location: Aston, PA

Job Type: Hybrid (Monday,Tuesday and Thursday on-site)

Reporting to: Senior Director, Product Development

Director Reports: N/A

Building our Future Together.

FXI is a leading producer of foam innovation in the 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?

Job Overview:

We are seeking a Manager of Scale-Up Engineering who works at the intersection of product development, engineering, and manufacturing. In this role, you will own the transition of new product concepts from prototypes and initial customer samples through successful, full-scale commercial production. The scope of this role includes supporting design for manufacturability, assessing process capability, leading pilot-scale feasibility runs and validating that manufacturing processes can consistently deliver the product as designed.

This position calls for a hands‑on engineer who combines technical rigor, practical problem-solving, and strong cross‑functional collaboration. The successful candidate will be comfortable working directly on the plant floor, translating product requirements into robust manufacturing solutions, and ensuring new products can be produced correctly the first time-and consistently thereafter.

Key Responsibilities:

• Drive the scale‑up of new products and processes from design for manufacturability through validated, full‑scale commercial production.
• Translate development‑stage designs into robust, documented, repeatable manufacturing specifications.
• Support the handoff to operations with validated processes, training, and the documentation required for a successful launch.
• Partner with plant teams to install, start up, and troubleshoot new manufacturing processes, and be the point person to resolve issues that impact products form, fit or function during ramp.
• Identify and resolve scale‑up challenges early, ensuring products and processes are robust and ready for commercial production.

Qualifications and Skills:

• Bachelor's degree in, Mechanical, Industrial, or Manufacturing Engineering, or a related field is required.
• 3+ years of experience in process or scale‑up engineering, with a preference for candidates with prior experience in polyurethane foam, bedding, or consumer goods manufacturing.
• Strong command of process development, validation, and scale‑up from pilot to full production.
• Working knowledge of process capability, statistical methods, and root-cause problem solving (e.g. Design of Experiments, Statistical Process Control, Root Cause Analysis & Failure Mode and Effects Analysis.)
• Proven project management skills and the ability to influence cross‑functional teams while managing multiple launches simultaneously.
• Willingness to work hands‑on across R&D, pilot, and plant environments, including travel to manufacturing sites as needed.

Desirable Traits and Skills:

• Excellent problem‑solving skills and a data‑driven approach to decision‑making.
• Demonstrates initiative and ownership in driving new processes from concept to reliable production.
• Deep knowledge of manufacturing processes, equipment, and design for manufacturability.
• Highly detail‑oriented with a proven track record of consistent follow‑through from trial to launch.
• Strong communicator, capable of conveying technical concepts clearly and collaborating with teams at all levels of the organization.

Total Rewards:

We offer a competitive salary and a comprehensive benefits package that includes:

• Medical, dental, and vision insurance
• Basic and optional life insurance
• Short and longterm disability coverage
• 401(k) plan with company match
• Tuition assistance
• Flexible spending accounts

Our Commitment to a Diverse Workforce:

FXI is an Equal Opportunity Employer. FXI does not discriminate in employment matters on the basis of race, color, religion, gender identity or expression, national origin, age, military service eligibility, veteran status, sexual orientation, marital status, disability, or based on any individual's membership in any group or class protected by applicable federal, state, or local laws. We support workplace diversity. We strongly believe that diversity contributes to a broader collective perspective that will consistently lead to a better company and better products. We are working hard to increase the diversity of our team wherever we can.

We are interested in every qualified candidate who is eligible to work in the United States. However, we are not able to sponsor visas.