Senior Control Engineer (Onsite - Acton)

Insulet Corporation•Acton, MA

9d•$118,700 - $178,025•Onsite

About The Position

The Senior Control Engineer provides engineering and technical expertise to maximize the contribution of Insulet’s USAM Plant Engineering Team. This role leads troubleshooting and continuous improvement of assembly and packaging equipment, process equipment, and high-speed automation applications. The engineer identifies root causes of complex technical issues and helps achieve output and yield-loss targets through daily improvements to existing equipment. The position requires someone self-driven, quick to learn, and able to balance varied projects in a dynamic, fast-growing environment. The Acton site is a global business headquarters and product development site where business functions and manufacturing are co-located with technical disciplines.

Requirements

Experience with Rockwell Automation (Allen-Bradley PLC/HMI).
Knowledge of machine vision systems for in-process product inspection.
Hands-on ability to set up an ABB robot application, including configuration, programming, and teaching.
Extensive experience engineering, troubleshooting, and continuously improving manufacturing equipment for high-volume, high-speed, high-precision assembly operations and complex industrial systems.
Bachelor of Science in Mechatronics, Electrical, or Electronics, or equivalent hands-on experience, and at least 5 years of hands-on experience with complex assembly and manufacturing equipment, including troubleshooting, root-cause analysis, and continuous improvement; or a Master of Science in Mechatronics, Electrical, or Electronics Engineering, or equivalent hands-on experience, and at least 3 years of such experience.
Ability to uphold safety standards, participate in continuous process improvement, and follow business best practices.
Ability to work in a collaborative and dynamic team environment.

Nice To Haves

Knowledge of Rockwell Automation RSLogix5000 and FTView ME and SE.
Knowledge of VFD and servo drives; Allen-Bradley PowerFlex and Kinetix preferred.
Experience with B&R controls software and hardware.
Extensive controls experience with automation, high-speed component feeding, and material handling.
Strong knowledge of servo motion-control concepts and robotics.
Proficiency in statistical analysis, including hypothesis testing and regression modeling, and exposure to machine-learning algorithms.
Familiarity with business intelligence tools such as Spotfire, Power BI, or Tableau.
Strong project management, organizational, and documentation skills.
Ability to multitask and maintain focus on priorities.
Solid communication and report-writing skills.

Responsibilities

Troubleshoot complex automation issues involving sensors, actuators, networks, safety circuits, and machine vision.
Develop, implement, and improve control systems, servo drives, motors, HMI systems, and PLC programs for high-speed assembly, packaging, and process equipment, working with the Controls GME team as needed.
Develop, collaborate on, and review wiring diagrams and logic for new equipment, field retrofits, and equipment upgrades.
Configure and develop machine vision systems for in-process product inspection, including PCs, frame grabbers, cameras, illumination, and motion-control interfaces, in collaboration with the Global Manufacturing Engineering team as needed.
Provide technical support for continuous improvement and Six Sigma projects related to Plant Operations.
Plan tasks, work independently, remain self-motivated, and respond effectively in a dynamic and fast-growing environment.
Support 24/7 operations during off-hours on an as-needed basis through phone support and remote troubleshooting.
Travel domestically and internationally as required; anticipated travel is estimated at 10%.