Lead Automation Engineer

Title: Lead Automation Engineer - Pharmaceutical Industry

Experience: 5+ Years

Location: MI

Job Summary:

Lead Automation Engineer with 5+ years of experience in pharmaceutical process automation, specializing in Emerson DeltaV Distributed Control System (DCS). Experienced in DeltaV system configuration, control module development, batch automation, graphics development, system commissioning, troubleshooting, and qualification support in GMP-regulated manufacturing environments.

Roles and Responsibilities:

• Lead automation engineering activities involving Emerson DeltaV DCS for pharmaceutical manufacturing processes and utility systems.
• Configure and maintain DeltaV control modules, equipment modules, phase logic, process control strategies, and interlocks based on approved functional specifications.
• Support DeltaV Batch configuration and recipe management for automated pharmaceutical manufacturing processes, including equipment phases, unit procedures, operations, and recipe execution, where applicable.
• Perform DeltaV system administration and configuration activities involving controllers, I/O cards, CHARMs, electronic marshalling, system architecture, and controller assignments.
• Configure and troubleshoot DeltaV I/O interfaces, field instrumentation, control valves, transmitters, and communication interfaces.
• Support integration with PLC-based equipment, skids, process instrumentation, historians, MES, and other plant systems using appropriate communication protocols.
• Lead and participate in Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, startup, and qualification activities.
• Prepare and review automation documentation, including URS, functional specifications, design specifications, control narratives, I/O lists, alarm matrices, test protocols, and configuration records.
• Support validation activities, including risk assessments, traceability matrices, IQ/OQ execution, deviation resolution, and Computer System Validation (CSV) documentation.
• Ensure DeltaV configurations meet pharmaceutical GMP requirements, GAMP 5 principles, FDA 21 CFR Part 11, applicable electronic record and electronic signature requirements, and site data integrity procedures.
• Troubleshoot DeltaV controller faults, module execution issues, communication failures, alarms, interlocks, I/O failures, and process control deviations to minimize manufacturing downtime.
• Support DeltaV system backups, configuration version control, disaster recovery, user access management, and periodic system reviews.
• Coordinate with Emerson service engineers, system integrators, OEMs, validation teams, and internal stakeholders for project execution and system support.
• Provide technical leadership, mentor junior automation engineers, review configuration deliverables, and ensure adherence to engineering standards and project timelines.

Required Qualifications:

• Bachelor’s degree in Instrumentation, Electrical, Electronics, Automation, or a related engineering discipline.
• 5+ years of experience in industrial automation, with strong hands-on expertise in Emerson DeltaV DCS.
• Experience in DeltaV configuration, troubleshooting, commissioning, and qualification support.
• Strong leadership, communication, analytical, and cross-functional coordination skills.