Staff Controls Engineer (Onsite)

Company Overview

Insulet started in 2000 driven to achieve our mission of enabling our customers to enjoy simplicity, freedom and healthier lives through the use of our Omnipod® product platform. In the last two decades we have improved the lives of hundreds of thousands of patients who have insulin-requiring diabetes, by using innovative technology that is wearable, waterproof, and lifestyle accommodating. We are on an exciting trajectory of significant growth and global expansion enabling us to reach more patients around the globe.

We are looking for highly motivated, performance driven individuals who want to be part of building our Center of Excellence and be at the forefront of our rapidly growing global footprint. We are looking to hire amazing people who are guided by shared values and desire to exceed customer expectations. Our continued success depends on it.

 

Position Overview

 

The Staff Controls Engineer will be responsible for owning and supporting industrial vision systems within a highly automated manufacturing environment. This role focuses heavily on Cognex-based vision applications as well as automation control systems that interface with robots, PLCs, motion systems, and MES/SCADA platforms. The ideal candidate has strong technical expertise in machine vision, industrial automation, and system troubleshooting, with a passion for driving quality and process reliability.

 

Responsibilities

 

Machine Vision Development & Integration

• Design, configure, and deploy Cognex and Keyence vision applications for automated inspection, measurement, and detection.

• Optimize lighting, optics, lenses, and camera placement for various product and process requirements.

• Design, develop and implement vision inspection systems as pass/fail criteria leveraging Cognex, Keyence and other integrated vision systems as appropriate.

• Validate and document vision performance including capability studies, FAI, and repeatability & reproducibility (R&R).

• Integrate machine vision systems with PLC platforms (e.g., Allen‑Bradley) and industrial robots (e.g., ABB, FANUC, YAMAHA).

• Support the commissioning of automated equipment and ensure vision systems communicate reliably with control and MES layers.

Automation & Controls Engineering

• Develop and modify PLC ladder logic, structured text, HMI screens, and system safety features as needed.

• Performs critical calculations such as timing requirements (scan rates), SCCR, Power Requirements, and Plant Loading

• Troubleshoot automation issues related to sensors, actuators, networks, safety circuits, and machine vision.

• Apply principles of electronics and electrical design, including digital, analog, RF, and mixed signal systems.

• Design, develop, implement and analyze high-speed automated manufacturing and test control systems including servo drives, HMI, PLC’s, equipment safety systems, robots, and data collection.

• Create schematics, wiring diagrams and design of machine controls, overseeing fabrication and assembly of prototypes with outside vendors related to new equipment, retrofits and upgrades.

Continuous Improvement & Reliability

• Lead root‑cause analysis and process optimization to improve yield, reduce false rejects, and enhance system uptime.

• Standardized vision templates, libraries, and best practices across manufacturing equipment.

• Provide training and technical support to maintenance, operations, and engineering teams.

Minimum Requirements:

• Bachelor’s degree in electrical engineering, Controls Engineering, Robotics, Computer Engineering, or related field.

• 10+ years of experience in highly automated industrial environments with strong Hands-on expertise with Cognex and Keyence platforms.

• Strong understanding of:

  • Industrial automation systems

  • PLC programming (Allen‑Bradley, Siemens, Mitsubishi, etc.)

  • Industrial networking (EtherNet/IP, Profinet, OPC-UA)

  • Robotics integration and system I/O

• Ability to interpret electrical schematics, mechanical drawings, and system architectures.

• Strong problem-solving, debugging, and analytical skills.

 

Preferred Skills and Competencies:       

• Advanced Programming knowledge of Rockwell Automation RSLogix5000 and FTView ME and SE required.

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

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

• Experience in a medical device or other regulated environment with validated processes is a plus.

• Strong project management, organizational and documentation skills desired.

Physical Requirements:              

• The successful candidate will be expected to travel domestically and internationally.  Anticipated travel is estimated at 15%.

•  This position requires on-site work in our Acton Manufacturing location.

• Able to work off shifts (nights/weekends), be on-call during off hours and have flexibility to come into plant when escalations require your physical support.   

  
   

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 $133,400.00 - $200,075.00 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.