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Lead Automation Controls Engineer
2 months ago
Insulet Corporation, founded with a vision to enhance the lives of our customers, is dedicated to providing innovative solutions through our Omnipod product platform. Over the years, we have positively impacted the lives of numerous patients by delivering cutting-edge technology that is adaptable, waterproof, and seamlessly integrates into their lifestyles.
We are seeking dynamic and results-oriented professionals to join our growing team. Our success is driven by exceptional individuals who share our values and consistently exceed customer expectations.
Position Overview:
The Global Manufacturing Engineering Group at Insulet is comprised of skilled professionals, advanced technologies, and inventive solutions that enhance the quality and performance of our unique drug delivery devices. The Senior Controls Engineer will serve as a key engineering and technical resource, optimizing the contributions of the Global Manufacturing Engineering Group to the overall performance of the company.
This role involves leading the development of Hardware/Software Controls for assembly and packaging equipment, process machinery, and high-speed applications. The ideal candidate will possess the ability to devise innovative solutions for diverse projects. Responsibilities include overseeing the installation and commissioning of new equipment, enhancing existing systems, and spearheading continuous improvement initiatives. Strong analytical and troubleshooting capabilities are essential, along with a self-motivated attitude and the ability to thrive in a fast-paced work environment, managing multiple projects simultaneously.
The Acton site serves as a global headquarters and product development center, co-locating all commercial, business functions, and manufacturing with technical disciplines, offering a wide array of career and professional development opportunities.
Key Responsibilities:
- Design, develop, and refine electro-mechanical systems and mechatronic devices, creating automated systems and software for control.
- Develop, install, and enhance control systems, servo drives, motors, HMIs, and PLC programs for high-speed assembly, packaging, and processing equipment.
- Collaborate on and review wiring diagrams and logic for new machinery, field retrofits, and upgrades.
- Engage in discussions on algorithmic control and mechanical design, as well as code reviews.
- Create tools to facilitate algorithm development, testing, and image quality evaluation.
- Innovate computer vision algorithms and advanced systems focusing on real-time object recognition, tracking, camera calibration, and 3D reconstruction.
- Configure vision systems, including PCs, frame grabbers, cameras, illumination, and motion control interfaces.
- Troubleshoot and enhance imaging programs for assembly and processing equipment.
- Utilize strong troubleshooting skills to identify root causes and define solutions.
- Conduct research and analyze data patterns for specifications, feasibility studies, and productivity enhancements using existing and self-developed data science tools.
- Perform statistical analysis, predictive modeling, and generate automated reports.
- Support data engineering in documentation and implementation of analytics tools.
- Provide technical support for continuous improvement and Six Sigma projects related to plant operations.
- Plan tasks independently, demonstrating self-motivation and adaptability in a dynamic environment.
- Bachelor's degree in Mechatronics, Electrical, Electronics Engineering, or a related field.
- 5+ years of hands-on experience with complex assembly and manufacturing equipment, including clean sheet design and continuous improvement implementation.
- Familiarity with Rockwell Automation, Keyence or Cognex vision software, and ABB Robotics.
- Extensive experience in engineering, design, and development of manufacturing equipment for high-volume, high-speed, high-precision assembly operations and complex industrial systems.
- Strong programming knowledge of Rockwell Automation RSLogix5000 and FTView ME and SE is preferred.
- Solid understanding of VFD and Servo drives (AB Powerflex and Kinetix preferred).
- Experience with B&R controls software and hardware is a significant advantage.
- Proficient in automation controls, high-speed component feeding, and material handling.
- Knowledge of visual computing tasks, including camera representations and related data processing, as well as 3D world to image mapping.
- Familiarity with leading model architectures and techniques across various domains, including image classification, object detection, and anomaly detection.
- Proficient in robot system design, including IO device selection and control component integration, creating power distribution and network architecture diagrams, and documenting operational sequences.
- Hands-on experience in setting up robot applications from scratch, including configuration, programming, and validation of automated sequences.
- Intermediate to advanced SQL skills, with comfort in manipulating large datasets directly in databases.
- Demonstrated proficiency in statistical analysis and exposure to machine learning algorithms is advantageous.
- Experience with analytic software tools is a plus.
- Familiarity with Visual Basic Programming and Business Intelligence tools (e.g., Spotfire, PowerBI, Tableau).
- Strong project management, organizational, and documentation skills.
- Ability to multitask while maintaining focus on priorities.
- Excellent communication and report writing skills.
- Commitment to safety standards and participation in continuous process improvement initiatives.
- Ability to work collaboratively in a dynamic team environment.
- The successful candidate should be prepared for domestic and international travel, estimated at 10%.
- We are committed to fostering the growth of our talented employees and encourage internal advancement whenever possible.