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This paper presents a novel method for PID (proportional–integral–derivative) controller auto-tuning based on expert knowledge incorporated into a fuzzy logic inference system. The proposed scheme iteratively tries to improve the performance of the closed-loop system. As performance measures, the proposed scheme uses the characteristics of the step response (rise time, overshoot, and settling time). PID parameters in the first iteration can be calculated based on the basic open-loop step response experiment or it is possible to use current parameters. In each successive iteration, step response characteristics are measured and the relative changes expressed in the percentage of value in the first iteration are calculated and converted into linguistic values. The fuzzy expert system computes fuzzy values that are used after defuzzification as multiplying factors for current PID parameters. To achieve a balance between the aggressive and robust closed-loop response, as well as between the slower and the faster one, the fuzzy expert system works in three operating modes: the one for speeding up the system, the one for reducing the overshoot, and the one for a balanced reduction of rise time and overshoot. The performance and robustness are verified by computer simulation using an extensive range of different processes. © 2022 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group.