Senior Specialist, Manufacturing Automation

Merck • Irving, TX

1d • $106,200 - $167,200

About The Position

The Senior Specialist, Manufacturing Automation provides technical leadership and automation support for capital projects and manufacturing operations at the Dallas, Texas, facility. The position supports startup, commissioning, qualification, operation, maintenance, and continuous improvement of manufacturing automation and mechanical systems. It is an individual-contributor role with responsibility for technical leadership, project execution, contractor oversight, and cross-functional coordination. The position reports to the Engineering Manager and works closely with the Associate Director of Operations, Maintenance, Operations, Quality, Information Technology, equipment suppliers, and other partners.

The role develops and improves automation strategies and systems, provides PLC/HMI and controls engineering support, and troubleshoots manufacturing equipment and system issues. It coordinates capital projects and supports equipment installation, startup, testing, commissioning, qualification, and transfer into routine operations. Responsibilities also include technical requirements and documentation, training users, and supporting operational readiness and audits.

The position is based primarily in Irving, Texas, with travel requirements stated as up to 30% in the qualifications and 25% in the posting details. It is a first-shift, day role, with flexible hours when needed. The work includes manufacturing and equipment areas, sometimes in non-climate-controlled spaces, and requires compliance with applicable safety and PPE requirements.

Requirements

• Bachelor’s degree in Engineering, Science, Information Technology, or a related technical discipline.
• At least seven years of relevant experience in process automation, manufacturing automation, controls engineering, or a related field.
• Experience developing, modifying, troubleshooting, and supporting PLC- and HMI-based control systems.
• Experience supporting equipment installation, startup, commissioning, qualification, or validation activities.
• Ability to interpret and develop technical specifications, system requirements, design documents, and operating procedures.
• Demonstrated ability to troubleshoot complex automation, equipment, and manufacturing-system issues.
• Strong written and verbal communication skills.
• Demonstrated technical leadership and experience leading project teams, contractors, consultants, or cross-functional workgroups.
• Strong time-management and organizational skills, including the ability to manage changing workloads and complete assignments independently.
• Demonstrated analytical, problem-solving, and decision-making skills, including the ability to act appropriately when faced with obstacles or ambiguity.
• Ability to travel up to 30%.
• Ability to work flexible hours when necessary to support project execution, equipment startup, manufacturing operations, or urgent technical issues.
• Ability to use handheld measuring and diagnostic devices; sit, stand, and walk for extended periods; occasionally lift and carry up to 50 pounds; climb stairs and ladders; and work at a computer for extended periods.
• Ability to work periodically in non-climate-controlled spaces and access manufacturing and equipment areas while following applicable safety and PPE requirements.
• Valid driving license.

Nice To Haves

• Experience in a regulated manufacturing environment.
• Experience developing or reviewing User Requirements Specifications, Functional Requirements Specifications, and Detailed Design Specifications.
• Experience with industrial networks, variable-frequency drives, data acquisition, system administration, and automation-system integration.
• Experience overseeing equipment suppliers, contractors, or automation consultants.
• Experience training operators, technicians, engineers, or other users of automated systems.

Responsibilities

• Evaluate automation and information technology systems and develop strategies to improve reliability, quality, maintainability, and long-term performance through expansion, replacement, or upgrades.
• Apply technical expertise to support safe, reliable, and efficient operation of automated processing equipment and supporting information technology systems.
• Identify and implement automation, process, and equipment improvements that increase manufacturing efficiency, reliability, and operational performance.
• Develop technical requirements that account for operational needs, system capabilities, lifecycle costs, business benefits, compliance requirements, and implementation risks.
• Serve as a liaison among site teams, corporate and divisional automation groups, and Information Technology.
• Develop PLC and HMI code for new equipment and support existing control systems.
• Configure and commission VFDs, subnet addressing, and industrial network communications.
• Provide on-floor technical support for manufacturing operations.
• Troubleshoot complex automation, controls, equipment, and system issues; develop sustainable corrective actions.
• Participate in investigations of automation anomalies, determine contributing factors, and implement actions to prevent recurrence.
• Analyze system performance, operating data, and equipment trends to identify emerging issues and improvement opportunities.
• Coordinate project activities across Engineering, Operations, Quality, Information Technology, procurement, suppliers, contractors, and other stakeholders to meet approved scope, schedule, cost, and compliance objectives.
• Provide technical leadership for equipment installation, startup, commissioning, qualification, and transfer into routine operations.
• Lead project coordination, troubleshooting, implementation, and change-control activities.
• Plan, attend, and execute vendor Factory Acceptance Testing and Site Acceptance Testing.
• Oversee contractors and consultants to ensure deliverables meet technical, quality, schedule, and customer requirements.
• Initiate and lead collaboration among Operations, Quality, Engineering, and technical teams to resolve complex technical and operational problems.
• Work with internal customers and stakeholders to define equipment and process requirements.
• Develop URS, FRS, and DDS documents for automation and equipment projects.
• Review and approve technical specifications and design documents prepared by suppliers, consultants, and other external providers.
• Support planning and execution of commissioning and qualification activities.
• Develop and update standard operating procedures and other technical documentation for project implementation and routine operations.
• Develop Job Safety Assessments as required.
• Support internal and external audits by preparing technical information, responding to automation-related observations, and implementing corrective actions.
• Develop and deliver training for operators, technicians, engineers, and other users of automated systems.
• Support operational readiness by ensuring systems, documentation, training, and technical support are in place before equipment is released for routine use.
• Participate in technical training programs and maintain current knowledge of relevant automation technologies, standards, and industry practices.
• Build effective working relationships and collaborate across organizational levels and functions; communicate complex technical information to technical and nontechnical audiences.
• Manage changing priorities and assignments while maintaining attention to quality, safety, schedule, and compliance; work independently and exercise sound judgment.
• Work flexible hours or outside standard business hours when required to support projects or manufacturing operations.

Benefits

• Medical, dental, and vision healthcare benefits and other insurance benefits for employees and families.
• Retirement benefits, including 401(k).
• Paid holidays.
• Vacation.
• Compassionate and sick days.
• Eligible for an annual bonus and long-term incentive, if applicable.
• Relocation available (domestic/international).
• Visa sponsorship available.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior