Principal Controls Engineer (Onsite)

Insulet Corporation•Acton, MA

7d•$142,800 - $214,200•Onsite

About The Position

Join a highly innovative, fast-growing medical device company where you’ll play a key role in advancing cutting-edge automation and robotics. As a Controls Engineer, you’ll design and enhance sophisticated electro-mechanical and vision-based systems that power high-speed manufacturing and packaging operations. This hands-on role offers the opportunity to work with advanced technologies—including PLCs, robotics, and computer vision—while driving continuous improvement and solving complex technical challenges. Ideal for driven engineers who thrive in dynamic environments, enjoy troubleshooting, and want to make a real impact on life-changing products. The Principal Controls & Instrumentation Engineer provides engineering and technical resource expertise in order to maximize the Automation Systems Group’s contribution to company performance. The Controls & Instrumentation Principal Engineer serves as one of the leaders of the technical community, working effectively and collaboratively with all technical disciplines and functions, both internally and externally, developing new technologies and processes for existing and new product production. This role is responsible to design, build and implement the most cost effective manufacturing controls hardware and software to meet the automation needs of a very dynamic and technically challenging business.

Requirements

In depth and prolonged experience in designing, debugging, specifying, selecting, manufacturing acceptance, installation, startup, commission and validation of control systems for fully automated and advanced discrete component assembly.
Sound technical skill set incorporating a breadth of automation control and instrumentation design principles.
Technical mastery in the field of engineering for automation controls systems.
Bachelor of Science in Electrical Engineering.
15+ years of hands-on automation controls design experience.
Solid problem solving skills.
Capable of responding to barriers, problems, and challenges with internal manufacturing or external equipment suppliers.
Able to effectively deal with conflict and openly communicate and lead team members to successful resolution.
Demonstrated ability to work effectively while leading others in a teaming environment across multiple geographical locations and across various functional areas and roles.
Strong verbal and written communication skills.

Nice To Haves

Master of Science in Electrical Engineering.
Having designed, built and implemented controls in a regulated and/or medical device industry.
Proven ability to manage multiple projects.
Strong Knowledge of VFD and Servo drives (AB & SEW preferred).
Experience with machine vision (Keyence and Cognex preferred).
Strong knowledge of PID loops and process control concepts.
Extensive knowledge of servo motion control concepts and robotics (ABB preferred).
SQL Server Database knowledge and Visual Basic Programming.
Solid understanding and demonstrated ability of implementing machine and process safety considerations.
Knowledge of CE, UL, SCCR & NFPA-70E&79 regulations.

Responsibilities

Design, development, specification and implementation of automation controls and instrumentation for assembly and packaging processes.
Continuous improvement efforts, obsolescence programs, technology transfers and new product development.
Design, debug, specify, select, perform manufacturing acceptance, installation, startup, commission and validation of control systems for fully automated and advanced discrete component assembly.
Development, design and hands-on technical aptitude of machine controls for newly built custom automation machines – significant exposure to industrial manufacturing environments.
Development, prototyping, simulation, design and troubleshooting of software and hardware controls including: electrical schematics, panel layouts, facility inputs, networking, device communications, Programmable Logic Controllers - Allen Bradley is a plus, Human Machine Interfaces, general purpose computers used in industrial applications, complex motion control, robotics programming, microprocessors, servo control, pneumatics, sensors and vision systems.
Development, testing, and implementation of PLC/SCADA application software for manufacturing processes, equipment, and systems.
Understand user requirements of complex types of products, translate these into a complete conceptualized automated value stream controls solution; Creates or coordinates the hardware and software design solutions for novel or complex problems; integrates regulatory and operational needs, and assesses cost benefit.
Management and oversight of vendor communications and collaboration.
Critically review engineering designs and ensure adherence to company design and development guidelines and Sops.
Build the capability of others to assure successful project execution.
Engage and energize others to reach their fullest potential and performance.
Improve business process systems, develop training aides and SOPs, and provide feedback to discipline owners for future designs.
Design and implement complex Machine Vision, Laser, and Measurement Systems to be utilized for quality control on high speed discrete component assembly equipment.
Troubleshoot to identify root cause and define solution.