Process Controls Engineer

fxiexternalsite; Fort Wayne (IN); On-site; USD 70,000 - 95,000; Full time

Job summary

FXI’s Fort Wayne facility seeks a Process Controls Engineer to optimize manufacturing processes and control systems. You will collaborate with operations, maintenance, quality, and engineering to reduce variation, scrap, and downtime while improving safety and efficiency.

The role is suited for an early- to mid-career engineer; experience with controls is preferred but advanced programming is not required. On-site work across three shifts at a union plant is possible.

Qualifications

• 0–5 years of engineering or manufacturing experience; internships, co-ops, or senior projects may be considered.
• Basic understanding of mechanical systems, manufacturing equipment, drawings, tolerances, and process troubleshooting.
• Ability to collect and analyze data, apply structured problem-solving, and turn findings into practical improvements.
• Strong communication, teamwork, organization, and follow-through on the manufacturing floor.

Responsibilities

• Spend time on the production floor observing equipment and workflows, engaging operators, and identifying practical improvement opportunities.
• Analyze process data and operating variables to identify sources of variation.
• Lead or support troubleshooting, root-cause analysis, trials, and corrective actions for safety, quality, delivery, and cost issues.
• Develop and maintain process settings, standard work, technical documentation, and training materials.
• Support equipment installation, commissioning, validation, and production handoff with internal resources, vendors, and contractors.

Skills

PLCs

HMIs

VFDs

Sensors

Industrial networks

Automated equipment

Allen-Bradley

PanelView

Wonderware

Ignition

Tools

AutoCAD

SolidWorks

SAP

Job description

Job Title: Process Controls Engineer

Location: Fort Wayne, IN

Job Type: On-Site

Reporting to: Lead Process Engineer

Director Reports: N/A

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?

Site Overview: 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 (2 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.

Position Summary:

The Process Controls Engineer supports manufacturing performance by improving processes, equipment, and control systems. This hands-on role works closely with operations, maintenance, quality, and engineering to reduce variation and scrap, improve safety and efficiency, and solve production problems. The position is intended for an early- to mid-career engineer; controls experience is preferred but advanced programming expertise is not required.

Key Responsibilities:

• Spend time on the production floor observing equipment and workflows, engaging operators, and identifying practical improvement opportunities.
• Analyze process data and operating variables such as temperature, pressure, speed, thickness, downtime, yield, and scrap to identify sources of variation.
• Lead or support troubleshooting, root-cause analysis, process trials, and corrective actions for safety, quality, delivery, and cost issues.
• Develop and maintain process settings, standard work, technical documentation, and training materials.
• Support mechanical improvements, tooling changes, equipment modifications, line layouts, and small-to-medium capital projects from concept through startup.
• Assist with equipment installation, commissioning, validation, and production handoff while coordinating internal resources, vendors, and contractors as assigned.
• Support PLC, HMI, VFD, sensor, and instrumentation troubleshooting and improvements in partnership with controls specialists or system integrators.
• Communicate project status and technical information clearly while building strong working relationships across operations, maintenance, quality, and engineering.

Required Qualifications:

• Approximately 0–5 years of engineering or manufacturing experience; relevant internships, co-ops, senior projects, and hands‑on technical experience will be considered.
• Basic understanding of mechanical systems, manufacturing equipment, drawings, tolerances, and process troubleshooting.
• Ability to collect and analyze data, apply structured problem‑solving, and turn findings into practical improvements.
• Strong communication, teamwork, organization, and follow‑through, with the ability to work safely and regularly on the manufacturing floor.
• Proficiency with Microsoft Office, particularly Excel, PowerPoint, and Word.

Preferred Qualifications:

• Exposure to PLCs, HMIs, VFDs, sensors, industrial networks, or automated equipment; Allen‑Bradley, PanelView, Wonderware, or Ignition experience is a plus.
• Experience with AutoCAD, SolidWorks, statistical analysis, process capability, or design of experiments.
• Experience supporting equipment installations, continuous production lines, web handling, roll processing, material handling, or polyurethane foam manufacturing.
• Basic project‑management experience and familiarity with SAP or a similar documentation system.

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 not accepting unsolicited assistance from search firms for this employment opportunity. Please, no phone calls or emails. All resumes submitted by search firms to any employee at FXI via-email, the Internet or in any form and/or method without a valid written search agreement in place for this position will be deemed the sole property of FXI. No fee will be paid in the event the candidate is hired by FXI as a result of the referral or through other means.