Senior Automation Engineer

Senior Automation Engineer

Device Assembly & Packaging

Position Summary

ASI is seeking a Senior Automation Engineer to provide technical ownership for controls and system integration associated with device assembly and packaging equipment. This engineer will be the bridge among OEM machines, line-level controls, robotics and vision, site SCADA/data systems, MES, scheduling, warehouse systems, and site IT/OT infrastructure. The role spans architecture and design review through FAT, SAT, automation verification, qualification, cut-over, startup, and operational support, with a strong emphasis on reliable integration, data integrity, machine safety, and rapid resolution of complex startup issues.

•      Own automation scope for assigned device assembly and packaging lines from design and vendor build through FAT, installation, SAT, qualification, startup, and performance ramp-up.

•      Review and approve OEM and integrator control-system architecture, PLC/HMI applications, electrical drawings, control panels, networks, interfaces, alarm strategies, safety circuits, robotics, vision systems, and cybersecurity provisions.

•      Provide technical leadership for controls associated with cartoners, case packers, packaging line modules, checkweighers, labelers, robotic literature-loading systems, tray unloaders, accumulators, barcode grading stations, conveyors, palletizers, stretch wrappers, and integrated line controls.

•      Lead integration of equipment and line controls with site platforms such as SCADA/data collection, MES, warehouse management, scheduling, Global Packaging Platform (GPP), GRIP, GPM, servers, databases, virtual infrastructure, networks, and middleware.

•      Define and verify interface requirements, data flows, recipes, equipment states, handshakes, alarms, audit trails, user access, backup/restore, time synchronization, electronic records, and failure/recovery behavior.

•      Develop or support automation deliverables such as user requirements, functional/design specifications, system configurations, traceability, risk assessments, alarm rationalization, action classification, parameter specifications, test scripts, security and recovery documentation, and turnover records.

•      Plan and execute or oversee FAT/SAT, loop and I/O checks, interlock and permissive testing, recipe and sequence testing, system-integration testing, IV/OV, data-integrity testing, automation cutovers, and startup troubleshooting.

•      Coordinate with Corporate Automation, Global Packaging & Robotics, Quality, IT/OT, MES teams, warehouse/logistics teams, OEMs, integrators, Operations, Maintenance, and CQV resources to resolve integration gaps and achieve startup milestones.

•      Support PSSR, machine-safety verification, electrical-safety reviews, network and infrastructure readiness, calibration and instrumentation readiness, and closure of automation punch-list items.

•      Troubleshoot PLC, HMI/SCADA, robotics, vision, server, database, network, middleware, MES, and equipment-interface issues using structured root-cause methods; document and implement sustainable corrective actions.

•      Establish lifecycle standards for source-code control, backups, disaster recovery, patching, access management, periodic review, change control, obsolescence, and operational support.

•      Mentor engineers and technicians and provide tertiary technical support during startup and commercial operations.

Requirements

Required Qualifications

•      Bachelor’s degree in electrical, automation, controls, computer, mechanical, or another relevant engineering discipline.

•      At least seven years of controls or process-automation engineering experience supporting highly automated manufacturing equipment.

•      Strong hands-on knowledge of Rockwell Automation platforms, including Studio 5000/ControlLogix and FactoryTalk View SE or comparable PLC/HMI technologies.

•      Demonstrated experience integrating OEM equipment with plant networks, SCADA/data historians, MES, databases, servers, virtual environments, and middleware.

•      Experience with FAT, SAT, commissioning, automation verification/qualification, system-integration testing, startup, and troubleshooting in a regulated or high-reliability manufacturing environment.

•      Working knowledge of industrial networking, machine safety, electrical/control-panel standards, data integrity, cybersecurity, backup/restore, and change management.

•      Strong technical leadership, vendor management, documentation, communication, and cross-functional problem-solving skills.

•      Ability to travel domestically or internationally to OEM facilities and provide flexible startup support when needed.

Preferred Experience

•      Pharmaceutical or medical-device cGMP manufacturing and familiarity with 21 CFR Part 11 and computer-system validation expectations.

•      High-speed secondary packaging, combination-product device assembly, robotics, machine vision, barcode verification, serialization, material handling, or automated palletization.

•      Rockwell-based packaging platforms and integration with MES, warehouse management, scheduling, and enterprise manufacturing applications.

•      Greenfield facility startup, global platform deployment, or multi-vendor equipment integration.