Senior Automation Engineer

Job Description
Senior Automation Engineer

Device Assembly & Packaging


Engagement

Contractassignment through Automated Systems, Inc. (ASI)

Location

KenoshaCounty, Wisconsin

Schedule

Monday-Friday;startup and rotational on-call support may be required

Travel

Approximately25-50% during vendor build/FAT and startup; lower after operational readiness

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.

Key Responsibilities
•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.