Sr Staff OT Systems Engineer (Onsite - Acton)

Insulet Corporation•Acton, MA

8d•$141,600 - $212,400•Onsite

About The Position

The Sr. Staff OT Systems Engineer provides technical leadership for the design, implementation, integration, and lifecycle support of Operational Technology systems used in automated manufacturing. The role combines knowledge of industrial controls—including PLCs, HMIs, industrial communications, and automated equipment—with experience supporting distributed OT systems and their infrastructure. Its global responsibilities include sites in the United States, Malaysia, and Costa Rica. The engineer works across machine controls, plant-floor systems, industrial networks, servers, databases, data platforms, and manufacturing applications. The role bridges Controls Engineering, Manufacturing, IT, Cybersecurity, Quality, equipment suppliers, and system integrators, and calls for hands-on troubleshooting from equipment and control systems through infrastructure, software, data flows, and applications. The engineer leads cross-functional projects, establishes technical standards, and delivers reliable, scalable, secure, maintainable, documented, and appropriately validated OT solutions. The Acton, Massachusetts site is a global business headquarters and product-development location where commercial and business functions, manufacturing, and technical disciplines are co-located. The position requires on-site office, plant, or lab work and approximately 10% to 20% domestic and international travel. The annual U.S. base salary range is $141,600 to $212,400; the position may also be eligible for incentive compensation. Actual pay depends on skills, experience, and education.

Requirements

Bachelor's degree in Electrical Engineering, Chemical Engineering, Computer Engineering, Computer Science, or a related technical discipline.
Ten or more years of experience in industrial automation, controls engineering, OT systems, or an equivalent combination of relevant education and experience.
Significant hands-on experience developing, commissioning, maintaining, or troubleshooting automation and OT systems in a manufacturing or industrial environment.
Experience with industrial automation software, communication gateways, data operations, and distributed software architectures.
Working knowledge of PLC-based equipment controls, HMI and SCADA systems, industrial communications, and machine-level data. Extensive PLC or motion-control programming is not required, but the candidate must understand equipment behavior and collaborate effectively with controls engineers and equipment suppliers.
Experience connecting manufacturing equipment to plant- or enterprise-level systems such as SCADA, historians, MES, databases, or industrial data platforms.
Experience supporting distributed OT applications, communication gateways, industrial data flows, or other software-based systems that collect, contextualize, transport, or consume manufacturing data.
Working knowledge of industrial Ethernet networks, managed switches, VLANs, TCP/IP, firewalls, and common industrial communication protocols.
Demonstrated ability to troubleshoot complex issues across equipment controls, communications, networking, software, infrastructure, data flows, and manufacturing applications.
Demonstrated ability to lead cross-functional technical initiatives and work effectively with Controls Engineering, Manufacturing, IT, Cybersecurity, Quality, equipment suppliers, engineering firms, and system integrators.
Strong project leadership, organizational, technical-writing, and stakeholder-communication skills.
Ability to translate technical requirements across controls, OT infrastructure, cybersecurity, manufacturing, quality, and external supplier teams.
Ability to work independently, manage competing priorities, and provide technical direction when systems and responsibilities cross organizational boundaries.

Nice To Haves

Experience with industrial PLC, HMI, and SCADA platforms, preferably Rockwell Automation platforms such as Studio 5000 / Logix and FactoryTalk View ME.
Experience with industrial communication gateways, edge-computing platforms, MQTT infrastructure, or Industrial DataOps platforms such as Litmus, HighByte, HiveMQ, or comparable technologies.
Strong understanding of industrial protocols and technologies such as EtherNet/IP, Modbus TCP, OPC UA, and MQTT.
Experience with industrial data modeling, ISA-95 concepts, Unified Namespace architecture, historians, SQL databases, and manufacturing data integration.
Working knowledge of Windows Server, Active Directory, virtualization, DNS, certificates, service accounts, storage, backup systems, and other infrastructure supporting OT applications.
Experience with industrial network architecture, managed industrial switches, VLAN segmentation, firewalls, secure remote access, and OT demilitarized-zone architectures.
Experience with scripting or programming languages such as Python, PowerShell, SQL, Visual Basic, or similar technologies used for system integration, testing, administration, or data analysis.
Experience with version-control, asset-management, or centralized backup platforms for industrial automation systems.
Experience in medical device, pharmaceutical, biotechnology, or another regulated manufacturing environment.
Knowledge of GxP practices, 21 CFR Part 11, Computer System Validation, Computer Software Assurance, data integrity, and risk-based change control.

Responsibilities

Provide technical leadership for the design, integration, implementation, and lifecycle support of manufacturing OT systems, including HMI and SCADA platforms, industrial networks, data-collection and application servers, databases, and interfaces between manufacturing equipment and plant or enterprise applications.
Integrate manufacturing equipment into the broader OT environment by applying knowledge of PLCs, equipment controls, industrial communications, and machine-level data to define interface requirements and coordinate with controls engineers, equipment suppliers, and system integrators.
Develop and maintain OT system architectures, network and data-flow diagrams, interface definitions, functional specifications, user requirements, design standards, and supporting engineering documentation.
Establish standardized, reusable interfaces between manufacturing equipment and higher-level systems, including historians, MES, databases, and other manufacturing applications.
Design and support industrial data architectures and integrations using technologies such as OPC UA, MQTT, SQL databases, historians, APIs, and managed file transfer.
Collaborate with IT and Cybersecurity teams to design and support OT networks and infrastructure, including segmentation, switching, routing, firewalls, remote access, servers, virtualization, identity management, backup, patching, monitoring, and recovery.
Diagnose complex issues across equipment controls, communications, infrastructure, software, data flows, and manufacturing applications, coordinating resolution with relevant internal teams, suppliers, and system integrators.
Support installation, integration, commissioning, qualification, startup, and operational turnover of manufacturing equipment and OT systems, emphasizing connectivity, data integration, infrastructure readiness, and long-term supportability.
Establish and support configuration management, version control, backup, disaster recovery, and change-management practices for OT systems, coordinating related equipment-level practices with controls engineers.
Partner with Quality and Validation teams to apply appropriate lifecycle controls for regulated manufacturing systems, including GxP, 21 CFR Part 11, Computer System Validation, Computer Software Assurance, and risk-based change control.
Lead technology evaluations, proof-of-concept activities, standards development, and continuous-improvement initiatives to improve OT-system consistency, interoperability, reliability, and maintainability across global manufacturing sites.
Provide technical guidance to engineering, maintenance, and other OT stakeholders, and contribute to OT technology roadmaps, platform strategies, lifecycle planning, and obsolescence management.