Sr. Manufacturing Engineer -Controls

Roche•Indianapolis, IN

2d•Onsite

About The Position

At Roche, we foster a culture where individuality is embraced, and personal expression, open dialogue, and genuine connections are encouraged. We aim to prevent, stop, and cure diseases and ensure global access to healthcare. The Near Patient Care division is dedicated to simplifying diabetes management through innovative products and comprehensive solutions. Internal Manufacturing Indianapolis, a key function within Roche Diagnostics, is responsible for strip manufacturing for global demand and will soon be responsible for sensor manufacturing for continuous glucose monitoring. This Sr. Manufacturing Engineer - Controls role is within the Equipment Performance team, focusing on leading continuous improvement projects, providing technical support for automated manufacturing equipment, troubleshooting, optimizing performance and reliability, and mentoring team members. The role also involves testing and validation to ensure compliance with Roche Diagnostics standards and regulatory requirements.

Requirements

Extensive hands-on experience troubleshooting and optimizing manufacturing equipment controls systems.
Proven track record of successfully diagnosing and resolving complex equipment challenges.
Electrical panels and systems
PLC ladder logic and structured text (preferably Allen Bradley PLCs using RSLogix/Studio 5000)
Motion Controls (e.g. VFDs, servos, etc.)
Human Machine Interface (HMI) (preferably FactoryTalk View SE/ME)
Vision Inspection (preferably Cognex Insight Explorer)
Distributed I/O (preferably Profibus/Ethernet IP)
Sensors (e.g. part presence/absence, position, process monitoring, etc.)
Comfortable modifying manufacturing equipment control system programs, configurations, and electrical systems to support continuous improvement and equipment reliability activity.
Skilled in working with vendors to identify improvement project solutions and obsolete component replacements.
Experienced in developing and executing equipment qualification requirements, testing, and documentation.
Experienced in collaborating with cross-functional teams to implement improvements, qualify changes, and resolve quality/downtime issues.
Ability to analyze test data and run simulations.
Ability to write and present clear and comprehensive technical documentation.
Highly analytical mind, with exceptional problem-solving skills and attention to detail.
Bachelor’s degree in Engineering or closely related discipline with 5 years relevant experience or Master’s of Engineering/PhD with 2 years relevant experience.
Relevant experience must include troubleshooting, modifying, and/or developing industrial equipment controls systems (PLCs, HMIs, Motion Control, etc.).

Nice To Haves

Previous experience troubleshooting controls systems of high volume/speed manufacturing equipment.
Familiar with GMP in a regulated environment (Medical Device or Pharmaceutical).
Previous training or experience in Process Improvement Methodologies (e.g. LSS, PDCA, etc.).
Demonstrates excellent interpersonal, communication, and teamwork skills.
Strong ability to teach and educate key stakeholders and other colleagues.
Deep commitment to cross-functional collaboration and breaking down silos to achieve the best results for the organization.

Responsibilities

Leads the development, implementation and maintenance of manufacturing methods, procedures and processes in the manufacture of products, components, subassemblies and final assemblies.
Develops and improves automation and electromechanical processes by studying requirements; researching and testing manufacturing and assembly methods and materials; and soliciting observations from operators and maintenance technicians.
Interfaces with design and process development engineering in coordinating the release of new products to the manufacturing process.
Helps to estimate manufacturing cost and makes recommendations for tooling, controls system hardware and software, and process requirements of new or existing production lines.
Manages multiple projects and time scopes for each project.
Ensures process changes are characterized and implemented following validation policies and procedures.
Assures system and product quality by designing testing methods; testing finished -product and system capabilities; and confirming fabrication, assembly, and installation processes.
Assists department leadership in setting strategic direction.
Possess and apply a broad knowledge of principles, practices, and procedures of the field.
Maintains product and company reputation by complying with government regulations.
Provide training, guidance, and advice to lower level staff.
Support key initiatives such as information management, cyber security, and life cycle management.
Participates in the on-call rotation to provide off shift / weekend support to production, as needed.