Staff Controls Engineer (Onsite)

Insulet Corporation•Acton, MA

1d•Onsite

About The Position

The Staff Controls Engineer will be responsible for owning and supporting industrial vision systems within a highly automated manufacturing environment. This role focuses heavily on Cognex-based vision applications as well as automation control systems that interface with robots, PLCs, motion systems, and MES/SCADA platforms. The ideal candidate has strong technical expertise in machine vision, industrial automation, and system troubleshooting, with a passion for driving quality and process reliability.

Requirements

Bachelor’s degree in electrical engineering, Controls Engineering, Robotics, Computer Engineering, or related field.
10+ years of experience in highly automated industrial environments with strong Hands-on expertise with Cognex and Keyence platforms.
Strong understanding of: Industrial automation systems PLC programming (Allen‑Bradley, Siemens, Mitsubishi, etc.) Industrial networking (EtherNet/IP, Profinet, OPC-UA) Robotics integration and system I/O
Ability to interpret electrical schematics, mechanical drawings, and system architectures.
Strong problem-solving, debugging, and analytical skills.
Able to work off shifts (nights/weekends), be on-call during off hours and have flexibility to come into plant when escalations require your physical support.

Nice To Haves

Advanced Programming knowledge of Rockwell Automation RSLogix5000 and FTView ME and SE required.
Strong Knowledge of programming of VFD and Servo drives and motion control. (AB Powerflex and Kinetix preferred).
Experience with B&R controls software and hardware a strong plus.
Experience in a medical device or other regulated environment with validated processes is a plus.
Strong project management, organizational and documentation skills desired.

Responsibilities

Machine Vision Development & Integration Design, configure, and deploy Cognex and Keyence vision applications for automated inspection, measurement, and detection.
Optimize lighting, optics, lenses, and camera placement for various product and process requirements.
Design, develop and implement vision inspection systems as pass/fail criteria leveraging Cognex, Keyence and other integrated vision systems as appropriate.
Validate and document vision performance including capability studies, FAI, and repeatability & reproducibility (R&R).
Integrate machine vision systems with PLC platforms (e.g., Allen‑Bradley) and industrial robots (e.g., ABB, FANUC, YAMAHA).
Support the commissioning of automated equipment and ensure vision systems communicate reliably with control and MES layers.
Automation & Controls Engineering Develop and modify PLC ladder logic, structured text, HMI screens, and system safety features as needed.
Performs critical calculations such as timing requirements (scan rates), SCCR, Power Requirements, and Plant Loading Troubleshoot automation issues related to sensors, actuators, networks, safety circuits, and machine vision.
Apply principles of electronics and electrical design, including digital, analog, RF, and mixed signal systems.
Design, develop, implement and analyze high-speed automated manufacturing and test control systems including servo drives, HMI, PLC’s, equipment safety systems, robots, and data collection.
Create schematics, wiring diagrams and design of machine controls, overseeing fabrication and assembly of prototypes with outside vendors related to new equipment, retrofits and upgrades.
Continuous Improvement & Reliability Lead root‑cause analysis and process optimization to improve yield, reduce false rejects, and enhance system uptime.
Standardized vision templates, libraries, and best practices across manufacturing equipment.
Provide training and technical support to maintenance, operations, and engineering teams.