Senior Automation Engineer

About the role

As a Senior Automation Engineer in the Global Equipment Engineering Group at Insulet, you will support both current manufacturing operations as well as new product development by providing expertise related to continuous improvement efforts for existing manufacturing processes and equipment. You will work with internal customers and external vendors to specify, procure, and install new manufacturing lines and equipment in accordance with business needs. You will work in a collaborative team environment with manufacturing, manufacturing engineering, metrology, quality and component supplier engineering.

Key responsibilities

• Design, develop, specify and implement automated equipment for assembly and packaging processes
• Support continuous improvement efforts, obsolescence programs, technology transfers and new product development in support of business objectives
• Specify, select, manufacturing acceptance, installation, startup, commission, and validate fully automated and advanced discrete component assembly and packaging technologies
• Manage and oversee vendor communications and collaboration; critically review engineering designs and ensure adherence to company design and development guidelines and SOPs
• Manage multiple projects and lead teams and vendors to achieve exceptional results
• Manage the IQ, OQ, FAT, SAT and PQ efforts for new assembly and packaging technologies and transferring technologies to new factory sites
• Build the capability of others to ensure successful project execution through improving business process systems, developing training aids and SOPs, and providing feedback to discipline owners
• Support capacity-expansion initiatives, including planning, specification, procurement, installation, and validation of new manufacturing lines and equipment
• Lead cross-site and cross-functional coordination to ensure alignment on technical deliverables, timelines, production readiness, and quality standards
• Serve as primary liaison for global project execution, bridging Global Automation Engineering with regional manufacturing sites
• Oversee commissioning, qualification, FAT, and SAT for new automation technologies and ensure successful transfer of equipment to new or existing factory sites
• Lead project planning for automation initiatives, including milestone creation, risk identification and mitigation, resource planning, and issue escalation
• Support capital project execution, including CAR development, budgeting, cost tracking, and forecast updates
• Execute and support technology transfers for manufacturing equipment being relocated or newly deployed at global sites
• Drive continuous improvement and obsolescence reduction programs
• Provide leadership and mentorship to project team members, onsite engineers, and vendor engineering teams

Preferred Requirements, Skills and Competencies:

• Experience in specifying, selecting, manufacturing acceptance, installation, startup, commission, and validation of fully automated and advanced discrete component assembly and packaging technologies
• Sound mechanical skillset incorporating machine design principles and strong mechanical aptitude
• Technical mastery in mechanical engineering, namely assembly technologies and packaging (blister forming, cartoning, bagging, sealing)
• Hands-on mechanical aptitude and machine design including pneumatics, linkage design, mechatronics, robotics, and drive systems
• Experience with process technologies: ultrasonic welding, heat transfer decoration, hot stamping, laser welding, laser decoration
• Knowledge of packaging: material knowledge, cartoning, conveyor systems and sealing technologies
• Demonstrated ability to understand user requirements of complex products, translate these into a complete conceptualized automated solution, and assess cost benefit
• Experience in a regulated and/or medical device industry is a plus
• Ability to manage and oversee vendor communications and collaboration
• Proven ability to manage multiple projects
• Experience with formal project management is a plus
• Ability to successfully lead teams and vendors to achieve exceptional results
• Good problem-solving skills and capability to respond to barriers, problems, and challenges
• Ability to effectively deal with conflict and openly communicate and lead team members to successful resolution
• Demonstrated ability to work effectively while leading others in a teaming environment across multiple geographical locations and across various functional areas and roles
• Strong verbal and written communication skills
• Solid understanding and demonstrated ability of implementing machine and process safety considerations
• Knowledge of CE, UL, SCCR, NFPA-70E and NFPA-79 regulations is a plus
• Demonstrated application of domestic and international standards (DIN, ASME, ISO) is a plus
• Bachelor of Science in Mechanical Engineering
• Master of Science in Mechanical Engineering is a plus
• 6+ years of hands-on machine design experience
• Demonstrated flexibility and ability to function in a fast-paced, growth industry and work environment
• Strong organizational skills
• Strong interpersonal skills
• Strong command of structured problem-solving tools
• Demonstrated proficiency in common computer tools such as word processing, spreadsheet, and web-based applications
• Proficiency with CAD modelling software (SolidWorks preferred)
• Working knowledge of Minitab and/or JMP statistical analysis software
• Experience with data analysis and data driven decision making
• Ability to lead cross-functional and cross-site technical activities, including vendor coordination and global project execution
• Strong project management capability, including scheduling, risk mitigation, and supporting capital project deliverables
• Experience with automation line startup and equipment commissioning, including debugging and validation
• Solid understanding of automation technologies such as robotics, motion systems, PLC-based equipment, and vision systems
• Working knowledge of machine and process safety requirements (CE, UL, NFPA)
• Ability to travel domestically and internationally as business needs demand (estimated at 30%)

About us

Insulet is the world's leading manufacturer of high-volume, disposable, electromechanical, wearable medical devices.