Staff Controls Engineer NPI

Insulet Corporation•Acton, MA

10d•$141,600 - $212,400•Onsite

About The Position

The Staff Controls Engineer NPI is a senior technical leader responsible for designing, integrating, and supporting Operational Technology (OT) systems for automated manufacturing equipment used in new product introductions and manufacturing scale-up. The role defines OT architecture, integration strategy, and lifecycle management to support the transition from development and pilot operations to commercial manufacturing. It bridges machine controls, manufacturing systems, and enterprise platforms through leadership in OT architecture, industrial networking, equipment connectivity, cybersecurity, and data integration. The position works closely with Manufacturing Engineering, Controls Engineering, IT, Cybersecurity, Quality, Operations, and external suppliers to deliver scalable, secure, and reliable manufacturing solutions. It provides technical leadership for OT systems that connect, monitor, secure, and support manufacturing equipment in a regulated manufacturing environment. The position is based in Acton, Massachusetts, with an expectation of at least four days per week onsite. It requires the ability to work in a Class 8 cleanroom as needed and approximately 10–20% domestic and international travel to manufacturing sites, suppliers, and system integrators. The annual base salary range for U.S.-based positions is $141,600–$212,400, and the role may also be eligible for incentive compensation.

Requirements

At least 8 years of hands-on experience in industrial automation, controls engineering, or OT systems within a manufacturing environment.
Proven experience designing and integrating OT systems that connect PLC, HMI/SCADA, MES, historians, databases, and industrial data platforms for automated manufacturing operations.
Strong expertise in industrial networking and communications, including EtherNet/IP, OPC UA, MQTT, TCP/IP, VLANs, managed switches, firewalls, and secure remote access.
Demonstrated success leading cross-functional OT initiatives involving Manufacturing Engineering, Controls Engineering, IT, Cybersecurity, Quality, and external equipment suppliers or integrators.
Bachelor's degree in Electrical Engineering, Computer Engineering, Computer Science, Automation Engineering, or a related technical discipline.
Ability to work in a Class 8 cleanroom environment as needed.
Ability to travel approximately 10–20%, including domestic and international travel.

Nice To Haves

Experience with Rockwell Automation platforms, including Studio 5000, Logix, and FactoryTalk, or comparable PLC, HMI, and SCADA systems.
Experience with Industrial DataOps platforms such as Litmus, HighByte, HiveMQ, or equivalent industrial data technologies.
Knowledge of ISA-95, Unified Namespace (UNS), and advanced manufacturing data architecture concepts.
Experience with Windows Server, Active Directory, virtualization, storage, backup, and OT infrastructure administration.
Experience using Python, PowerShell, SQL, or similar scripting and automation tools.
Knowledge of GxP, 21 CFR Part 11, Computer System Validation (CSV), Computer Software Assurance (CSA), and data integrity requirements.
Experience supporting medical device, pharmaceutical, biotechnology, or other regulated manufacturing environments.
Experience supporting new product introductions, manufacturing scale-up initiatives, and automated assembly systems.

Responsibilities

Lead the OT strategy, architecture, and technical roadmap for NPI manufacturing programs.
Design, implement, integrate, and support OT systems, including HMI/SCADA platforms, industrial networks, data collection systems, historians, databases, and enterprise interfaces.
Establish standardized connectivity between manufacturing equipment and higher-level systems, including MES, SCADA, historians, databases, and industrial data platforms.
Partner with IT and Cybersecurity to implement secure, scalable OT infrastructure, including networking, remote access, virtualized environments, backup, monitoring, and disaster recovery solutions.
Drive equipment integration from specification through FAT, SAT, installation, validation, startup, and operational turnover.
Lead resolution of complex technical issues spanning controls, communications, software, networking, and manufacturing applications.
Develop and maintain OT standards, system documentation, interface specifications, network diagrams, and lifecycle management processes.
Partner with Quality and Validation teams to ensure compliance with regulated manufacturing requirements.
Evaluate emerging technologies and lead continuous improvement initiatives to enhance system reliability, scalability, maintainability, and security.
Provide technical leadership and mentoring across engineering, operations, and maintenance teams.