Senior Control Engineer (Onsite - Acton)

insulet; United States; On-site; USD 110,000 - 160,000; Full time

Job summary

Insulet is seeking an experienced Senior Controls Engineer for the USAM Plant Engineering team. You will lead troubleshooting and continuous improvement of assembly, packaging, and process equipment, focusing on high-speed automation and robust control systems to maximize output and quality.

The role requires hands-on experience with Rockwell/Allen-Bradley PLCs, machine vision, ABB robotics, and advanced control strategies.

Qualifications

• Bachelor of Science in Mechatronics, Electrical, or Electronics or equivalent hands-on experience.
• 5+ years of experience in relevant field.

Responsibilities

• Troubleshoot complex automation issues related to sensors, actuators, networks, safety circuits, and machine vision.
• Develop, implement, and improve control systems, servo drives, motors, HMIs and PLCs on high-speed assembly, packaging, and process equipment.
• Develop, review wiring diagrams and logic for new equipment and upgrades.
• Configure and develop machine vision systems for in-process inspection.
• Support continuous improvement and six sigma projects in Plant Operations.
• Plan tasks, be independent, and adapt quickly in a dynamic, fast-growing environment.

Skills

Rockwell Automation

Machine vision

ABB robot

High-speed assembly

Continuous improvement

Statistical analysis

Project management

Safety standards

Team collaboration

Education

Bachelor of Science in Mechatronics / Electrical / Electronics

Tools

RSLogix5000

FTView ME

FTView SE

Kinetix / Powerflex

B&R controls

Job description

Job Summary

Join Insulet and play a key role in advancing the automation behind life-changing medical devices. This high-impact opportunity is ideal for an experienced Controls Engineer who enjoys solving complex manufacturing challenges, working with cutting‑edge automation technologies, and driving continuous improvement in a fast‑paced, high‑growth environment.

Company Overview

Insulet started in 2000 driven to achieve our mission of enabling our customers to enjoy simplicity, freedom and healthier lives through the use of our Omnipod® product platform. In the last two decades we have improved the lives of hundreds of thousands of patients who have insulin‑requiring diabetes, by using innovative technology that is wearable, waterproof, and lifestyle accommodating. We are on an exciting trajectory of significant growth and global expansion enabling us to reach more patients around the globe.

We are looking for highly motivated, performance driven individuals who want to be part of building our Center of Excellence and be at the forefront of our rapidly growing global footprint. We are looking to hire amazing people who are guided by shared values and desire to exceed customer expectations. Our continued success depends on it.

Position Overview

The USAM Plant Engineering Team showcases talented professionals, world‑class technologies, and innovative solutions that \"power\" the quality and performance of Insulet Corporation's unique drug delivery devices. The Senior Controls Engineer provides engineering and technical resource expertise to maximize the engineering team's contribution to company performance.

The Senior Control Engineer will lead troubleshooting and continuous improvement of assembly and packaging equipment, process equipment and high‑speed automation applications. Ability to find root causes of complex technical issues is needed. The candidate will be responsible for helping to ensure output and yield loss targets are achieved through daily improvements to existing equipment. The candidate must be self-driven, quick to learn and able to perform in a very dynamic work environment, balancing a wide variety of projects and work activities.

The Acton site is a global business HQ and product development site with all commercial, business functions and manufacturing co‑located with all technical disciplines. This offers a broad range of career and experience building opportunities.

Responsibilities

• Troubleshoot complex automation issues related to sensors, actuators, networks, safety circuits, and machine vision.
• Develop, implement, and improve control systems, servo drives, motors, HMIs and PLCs programs on high‑speed assembly, packaging, and process equipment working in partnership with the Controls GME team as needed.
• Develop, collaborate on, and review wiring diagrams and logic for new equipment, field retrofits, and equipment upgrades.
• Configure and develop machine vision systems for in‑process product inspection (PC, frame grabbers, cameras, illumination, motion control interfaces) in collaboration with the Global Manufacturing Engineering team as needed.
• Provide technical support for continuous improvement and six sigma projects related to Plant Operations.
• Ability to plan tasks, be independent, self‑motivated and respond in a dynamic and fast‑growing environment.

Required Skills and Competencies

• Experience with Rockwell Automation (Allen Bradley PLC/HMI).
• Knowledge of machine vision systems for in‑process product inspection purposes (Keyence/Cognex preferred).
• Hands‑on ability to setup an ABB robot application including configuration, programming, and teaching.
• Extensive experience in engineering, troubleshooting, and continuous improvement of manufacturing equipment for high volume, high speed, high precision assembly operation and complex industrial systems.

Preferred Skills and Competencies

• Knowledge of Rockwell Automation RSLogix5000 and FTView ME and SE highly preferred.
• Knowledge of VFD and Servo drives. (AB Powerflex and Kinetix preferred).
• Experience with B&R controls software and hardware is a strong plus.
• Extensive experience in controls of automation, high‑speed component feeding, material handling
• Strong knowledge of servo motion control concepts and robotics
• Demonstrated proficiency in statistical analysis (hypothesis testing, regression modeling) and exposure to machine learning algorithms is a plus
• Familiarity with Business Intelligence tools a plus (e.g. Spotfire, PowerBI, Tableau)
• Strong project management, organizational and documentation skills
• Ability to multitask and maintain focus on priorities.
• Solid communications and report writing skills
• Ability to uphold Safety standards, to participate in Continuous Process Improvement on the job, and to follow our business best practices.
• Ability to work in a collaborative and dynamic team environment

Education and Experience

• Bachelor of Science in Mechatronics, Electrical, or Electronics or equivalent hands‑on experience
• 5+