Process & CI (Lean) Engineer

FXI; Indiana, Northern (PA, KY); Hybrid; USD 85,000 - 120,000; Full time

Benefits offered by this job

Health, dental, vision insurance

401(k) match

Disability insurance

Tuition assistance

Flexible spending accounts

Job summary

FXI in Auburn, IN seeks a Process & Continuous Improvement (LEAN) Engineer to lead capital projects and CI initiatives, driving throughput, quality and equipment reliability. You will link engineering, maintenance and manufacturing to implement value stream mapping, 5S, standard work and kaizen events across the plant.

This role also provides technical support for troubleshooting electromechanical, HVAC and fluid-chemical systems; manages the site capital plan and supports 24/5 operations with a

Qualifications

• Bachelor’s degree in mechanical or electrical engineering or related discipline; equivalent combo considered.
• Minimum 5 years of manufacturing shop floor experience.
• Capital project management experience: scoping, cost estimating, installation, commissioning.
• Demonstrated machine and equipment troubleshooting skills.
• Ability to build capital appropriation requests with ROI justification.
• LEAN/ Six Sigma experience; certification preferred.
• Proficiency with MS Office, AutoCAD, SAP, and Allen-Bradley PLCs.
• Willingness to travel up to 10%.

Responsibilities

• Develop capital project justifications, scopes of work, cost estimates, and schedules; manage approved projects to budget and timeline.
• Manage equipment specification, vendor selection, installation, commissioning, validation, and training.
• Lead LEAN continuous improvement activities: value stream mapping, kaizen events, 5S, standard work, SMED, visual management.
• Apply structured problem-solving methods (A3, DMAIC, 5-Why, fishbone) to eliminate losses.
• Establish and track process metrics (OEE, scrap, cycle/changeover time); report savings to site leadership.
• Document process changes and update SOPs, flows, and layouts.

Skills

Shop floor experience

Capital project management

LEAN/CI experience

Troubleshooting

ROI/Cost analysis

Problem-solving (A3, DMAIC)

Travel readiness

Education

Bachelor’s degree in mechanical or electrical engineering

Tools

AutoCAD

SAP

Allen-Bradley PLCs (SLC-500, 5000, MicroLogix)

MS Office

Manufacturing software

Job description

Job Title: Process & Continuous Improvement (LEAN) Engineer

Location: Auburn, IN

Job Type: On-Site

Reporting to: Plant Manager

Company Overview

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 Summary

The Process & Continuous Improvement (LEAN) Engineer leads capital projects and LEAN continuous improvement initiatives that increase throughput, quality, and equipment reliability. This position manages capital projects from justification and scoping through installation, commissioning, and hand-off to operations, and serves as a key link between engineering, maintenance, and manufacturing centers. The Process & CI Engineer drives measurable improvement in downtime, scrap, and productivity through structured problem solving and LEAN methods.

This position will lead the plant engineering function supporting a 24/5 operation. The Process & CI Engineer serves as the key technical resource for the manufacturing operation, owning the site capital plan and leading the plant's continuous improvement program — value stream mapping, standard work, 5S, kaizen events, and root cause analysis. This role also provides technical support for troubleshooting and problem resolution of electronic, mechanical, HVAC, and fluid-chemical transfer systems.

Key Responsibilities

• Develop capital project justifications, scopes of work, cost estimates, and schedules; manage approved projects to budget and timeline.
• Manage equipment specification, vendor selection, installation, commissioning, validation, and operator training for new and modified assets.
• Lead LEAN continuous improvement activity — value stream mapping, kaizen events, 5S, standard work, SMED, and visual management.
• Apply structured problem-solving methods (A3, DMAIC, 5-Why, fishbone) to eliminate recurring quality, throughput, and downtime losses.
• Establish and track process performance metrics (OEE, scrap, cycle time, changeover time) and report savings and progress to site leadership.
• Document process changes and update standard operating procedures, process flows, and layouts.

Skills / Qualifications:

• Bachelor’s degree in mechanical or electrical engineering or a related discipline or, an equivalent combination of work experience, training and/or education may be considered.
• Minimum of five (5) years of manufacturing shop floor experience.
• Prior capital project management experience, including scoping, cost estimating, equipment installation, and commissioning.
• Demonstrated machine and equipment troubleshooting skills.
• Ability to build capital appropriation requests and cost/benefit analyses, including payback and ROI justification.
• Demonstrated experience leading LEAN continuous improvement activity (value stream mapping, kaizen, 5S, standard work) and applying structured problem-solving methodologies; Six Sigma or LEAN certification preferred.
• Proficient in Computer applications; specifically, MS Office, Autocad, Manufacturing software, SAP system, Allen/Bradley PLCs to include: SLC-500 and 5000, and Micro-logics
• Willingness to travel up to 10% to support other facilities if needed.

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 long‑term 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.

FXI is an equal opportunity employer. We are committed to providing an inclusive and diverse workplace where all individuals are treated with respect and have equal opportunities for employment and advancement. FXI prohibits discrimination and harassment of any kind based on race, color, religion, sex, national origin, age, disability, genetic information, veteran status, sexual orientation, gender identity, or any other characteristic protected by applicable law.