Senior Controls Engineer (Onsite)

Job Summary

Join a highly innovative, fast-growing medical device company where you’ll play a key role in advancing cutting-edge automation and robotics. As a Controls Engineer, you’ll design and enhance sophisticated electro-mechanical and vision-based systems that power high-speed manufacturing and packaging operations. This hands-on role offers the opportunity to work with advanced technologies—including PLCs, robotics, and computer vision—while driving continuous improvement and solving complex technical challenges. Ideal for driven engineers who thrive in dynamic environments, enjoy troubleshooting, and want to make a real impact on life-changing products.



The Global Manufacturing Engineering Group showcases talented professionals, world-class technologies, and innovative solutions that “power” the quality and performance of Insulet Corporation’s unique drug delivery devices.  The Sr. Controls Engineer provides engineering and technical resource expertise in order to maximize the Global Manufacturing Engineering Group contribution to company performance.

The Senior Control Engineer will lead in Hardware/Software Controls development utilized on assembly and packaging equipment, process equipment and high-speed applications.  Ability for creating new solutions for every project is needed.  The candidate will be responsible for leading the installation and start-up of new equipment, improvements to existing equipment and other continuous improvement initiatives.  This position requires strong analytical and troubleshooting skills.  The candidate must be self-driven and 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:

• Design, develop, and enhance electro-mechanical systems and mechatronic devices, creating automated systems and software to control them

• Develop, Install, and improve control systems, servo drives, motors, HMIs and PLCs programs on high speed assembly, packaging, and process equipment.

• Develop, collaborate on, and review wiring diagrams and logic for new equipment, field retrofits, and upgrades.

• Actively participate in algorithmic, control, mechanical design discussions and code reviews.

• Develop tools to assist with algorithm development, algorithm testing, and image quality evaluation and validation

• Develop novel, accurate computer vision algorithm and advanced systems with a focus on real-time object recognition, object tracking, camera calibration and 3D reconstruction

• Configure vision systems (PC, frame grabbers, cameras, illumination, motion control interfaces)

• Troubleshoot, continuously improve, and create imaging programs for assembly and processing equipment

• Utilize excellent troubleshooting skills with a hands-on approach to identify root cause and define solution

• Research, explore and analyze data patterns programs for specifications, feasibility studies, and productivity improvements using existing data science tools and self-created programs

• Perform statistical analysis, predictive modeling, and generate automated reporting.

• Assist data engineering in documentation and data catalog and implementation of analytics tools.

• Technical support of continuous improvement and six sigma projects related to Plant operations.

• Ability to Plan task, be independent, self-motivated and respond in a dynamic and fast growing environment

Minimum Requirements:

• Bachelor of Science in Mechatronics, Electrical, Electronics Engineering preferred or in lieu of education 5+ years of hands on complex assembly and manufacturing equipment experience including clean sheet design, design, and implementation of continuous improvement for discrete component assembly equipment.

• Experience with Rockwell Automation, Keyence or Cognex vision software and ABB Robotics.

Preferred Skills and Competencies:

• Extensive experience in the engineering, design, and development of manufacturing equipment for high volume, high speed, high precision assembly operation and complex industrial systems

• Strong Programming knowledge of Rockwell Automation RSLogix5000 and FTView ME and SE preferred.

• Strong Knowledge of VFD and Servo drives.  (AB Powerflex and Kinetix preferred)

• Experience with B&R controls software and hardware a strong plus.

• Extensive experience in controls of automation, high-speed component feeding, material handling

• Strong knowledge of servo motion control concepts and robotics

• Knowledge of visual computing tasks, such as camera representations and related data processing, 3D world to image mapping.

• Knowledge of leading model architectures and techniques across a broad range of domains, including image classification, object detection, image segmentation, anomaly detection and object tracking is a plus

• Proficiency in robot system design including selection of IO devices and controls components, creating power distribution and network architecture diagrams, creating detailed electrical schematics, documenting sequence of operation and functional requirements.

• Hands-on ability to setup a robot application from scratch including configuration, programming, teaching, safeguarding and validation of automated sequences

• Intermediate/advanced SQL skills, comfortable manipulating/merging large datasets directly in the database

• Demonstrated proficiency in statistical analysis (hypothesis testing, regression modeling) and exposure to machine learning algorithms is a plus

• Experience in one or more analytic software tools is a plus

• Familiarity with Visual Basic Programming and Business Intelligence tools (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

Physical Requirements:

• The successful candidate will be expected to travel domestically and internationally. Anticipated travel is estimated at 10%.

NOTE: This position requires on-site working (requires on-site office/plant/lab work). #LI-Onsite

Additional Information:



Compensation & Benefits:

For U.S.-based positions only, the annual base salary range for this role is $118,700.00 - $178,025.00

This position may also be eligible for incentive compensation.

We offer a comprehensive benefits package, including:
• Medical, dental, and vision insurance
• 401(k) with company match
• Paid time off (PTO)
• And additional employee wellness programs

Application Details:
This job posting will remain open until the position is filled.
To apply, please visit the Insulet Careers site and submit your application online.

Actual pay depends on skills, experience, and education.