Senior Controls Engineer
About The Position
Position Summary Provides technical leadership for automated process control systems (APCS) supporting pharmaceutical manufacturing operations, including Fabrication, Filling, Overwrap, Sterilization, Packaging, and Utilities systems. Responsible for improving system performance, reliability, compliance, and safety through evaluation and enhancement of PLC, HMI, and robotic control systems. Leads troubleshooting, system optimization, and implementation of automation solutions. Works closely with Maintenance, Operations, and Validation to ensure systems remain in a validated state and operate efficiently within a GxP-regulated environment. Provides project leadership for automation-related capital and continuous improvement initiatives. Essential Duties & Responsibilities Analyzes, designs, and implements control systems for complex manufacturing equipment, including PLCs, HMIs, SCADA, and robotic systems (e.g., Fanuc). Develops functional specifications, control narratives, and design documentation for automation systems in compliance with site and corporate standards. Provides technical leadership (SME) for APCS across multiple manufacturing processes; leads troubleshooting of equipment and system issues. Evaluates existing automation systems and implements improvements to increase reliability, efficiency, and compliance. Develops and executes automation strategies for capital projects, including scope development, design, FAT, SAT, commissioning, and validation support. Integrates multiple subsystems (PLC, HMI, vision systems, robotics, and field devices) into cohesive, reliable control systems. Ensures all automation changes are performed in accordance with change control and software validation procedures). Leads and manages automation project timelines, provides status updates, and communicates risks to site leadership. Supports validated systems by maintaining software lifecycle documentation, backups, version control, and audit readiness. Identifies and drives continuous improvement initiatives for automation systems and manufacturing processes. Collaborates with Maintenance to improve equipment uptime, PM strategies, and troubleshooting effectiveness. Provides technical training and knowledge transfer to engineers, maintenance, and operations personnel. Leads or supports deviation investigations, root cause analysis, and CAPA implementation related to control systems. Communicates effectively across functions and escalates risks or issues as needed. Works on special projects as assigned.
Requirements
- Advanced knowledge of PLC programming (e.g., Rockwell, Siemens), HMI/SCADA systems, and industrial networking
- Strong understanding of automation system integration and troubleshooting
- Working knowledge of GxP regulations, validation practices, and change control processes
- Ability to manage multiple projects and priorities in a regulated manufacturing environment
- Strong analytical and problem-solving skills with ability to implement practical, compliant solutions
- Effective communication and cross-functional collaboration skills
- Bachelor’s Degree in Engineering required (Electrical, Computer, or related discipline preferred)
- Minimum of 10 years of experience in controls/automation engineering
- Must be at least 18 years of age
Nice To Haves
- Experience with robotic systems (e.g., Fanuc), vision systems, and motion control preferred
- Experience in pharmaceutical or other regulated manufacturing environments strongly preferred
- Experience with validated systems and software lifecycle management preferred
Responsibilities
- Analyzes, designs, and implements control systems for complex manufacturing equipment, including PLCs, HMIs, SCADA, and robotic systems (e.g., Fanuc).
- Develops functional specifications, control narratives, and design documentation for automation systems in compliance with site and corporate standards.
- Provides technical leadership (SME) for APCS across multiple manufacturing processes; leads troubleshooting of equipment and system issues.
- Evaluates existing automation systems and implements improvements to increase reliability, efficiency, and compliance.
- Develops and executes automation strategies for capital projects, including scope development, design, FAT, SAT, commissioning, and validation support.
- Integrates multiple subsystems (PLC, HMI, vision systems, robotics, and field devices) into cohesive, reliable control systems.
- Ensures all automation changes are performed in accordance with change control and software validation procedures).
- Leads and manages automation project timelines, provides status updates, and communicates risks to site leadership.
- Supports validated systems by maintaining software lifecycle documentation, backups, version control, and audit readiness.
- Identifies and drives continuous improvement initiatives for automation systems and manufacturing processes.
- Collaborates with Maintenance to improve equipment uptime, PM strategies, and troubleshooting effectiveness.
- Provides technical training and knowledge transfer to engineers, maintenance, and operations personnel.
- Leads or supports deviation investigations, root cause analysis, and CAPA implementation related to control systems.
- Communicates effectively across functions and escalates risks or issues as needed.
- Works on special projects as assigned.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
Number of Employees
5,001-10,000 employees
