Lead Automation Engineer

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Job Description

Lead Automation Engineer to manage and deliver the complete automation scope for a Greenfield manufacturing facility, from Basic Design through Detailed Engineering, Procurement Support, Installation, FAT, SAT, Commissioning, and Handover.

The role requires strong technical and leadership experience in industrial automation systems with clear accountability for Safety, Quality, Schedule, and Cost. The Lead Automation Engineer will act as the single-point owner for automation packages, manage delayed package recovery, and control Scope Change Orders (SCOs) related to automation.

Tasks and responsibilities

1. Design Management (Basic to Detailed Engineering)

Lead Basic and Detailed Automation Engineering activities with OEMs, system integrators, and internal SMEs.

Ensure completeness and quality of P&IDs, Control Narratives, I/O Lists, Instrument Index, Logic Diagrams, and HMI philosophies.

Leading an area with a team- setting direction, planning, execution & handover.

Review and approve automation deliverables for constructability, operability, maintainability, and compliance.

Drive Design Reviews and ensure outputs support timely procurement and installation.

2. Automation Package Execution (DCS / PLC / SCADA / Batch Systems)

Act as technical owner for automation systems including DCS, PLC, SCADA, EMS, and Batch Management systems as applicable.

Define and review Batch Automation architecture in line with ISA-88/95 standards.

Acting as subject matter experts in own discipline.

Supervising/Development of functional specification of complex units.

Lead implementation of Batch Manager / Batch Executive systems including recipe design, master recipes, control recipes, and equipment models.

Supervising/Developing DCS application coding based on programming standards and design guidelines.

Coordinate with Process owners for software development, batch configuration, documentation, licenses, and spares.

Ensure alignment of automation and batch system deliveries with project schedule and construction readiness.

3. Installation, FAT, SAT, and Commissioning Support

Plan, execute, and lead Factory Acceptance Tests (FAT) for both continuous and batch automation systems, including recipe testing and batch execution scenarios.

Support site installation activities such as panel installation, cabling, loop checks, and system power-up.

Lead or support Site Acceptance Testing (SAT), batch logic testing, interlock verification, and commissioning activities.

Support batch process dry runs, water batches, and process simulation prior to live production.

Ensure structured automation and batch system handover including as-built documents, recipes, backups, passwords, and operator training.

4. Safety, Quality, and Compliance Assurance

Enforce strict adherence to EHS protocols at all phases — zero compromise on safety.

Ensure implementation of QA/QC standards, including ITPs, checklists, audits, and NCR closures.

Coordinate with Safety and Quality teams to ensure all works meet regulatory and internal standards.

5. Schedule Control (Non-Negotiable)

Own automation milestones within the Integrated Master Schedule.

Develop and track 2W / 4W / 6W look-ahead schedules for automation engineering, FAT, SAT, and commissioning.

Identify schedule risks early and drive recovery plans for delayed automation packages or vendo

6. Cost Control and Scope Change Order (SCO) Management

Monitor automation package costs against approved budgets.

Evaluate technical impact of scope changes, design modifications, and recovery actions.

Act as automation focal point for SCO documentation, justification, impact analysis, and approvals.

7. Risk Management & Early Forecasting

Maintain a live project risk register with active mitigation plans.

Proactively identify interface risks with Process, Electrical, Instrumentation, IT/OT, Utilities, and Validation teams.

Escalate risks that could impact commissioning readiness or plant start-up timelines.

8. Project Governance & Stakeholder Management

Organize and lead status meetings, design reviews, site reviews, and cross-functional syncs.

Coordinate with vendors, consultants, internal teams, and Global Team.

repair and present weekly and monthly automation status reports, dashboards, and recovery trackers.

Basic Qualifications

Bachelor’s Degree in Instrumentation, Electrical, Electronics, or Automation Engineering.

Minimum 10–15 years of experience in industrial automation project execution.

Proven experience in Greenfield projects from design through commissioning.

Strong working experience with PLC/DCS/SCADA systems (ABB 800xA, Emerson or equivalent).

Proven experience in Batch Automation and Batch Management systems (ISA-88/95), including recipe configuration, unit procedures, phases, and batch execution.

Process engineering knowledge for liquid systems (pumps, valves, CIP/SIP)

Knowledge of ABB800xA system, ABB Batch manager, PCDL, PCEL libraries would be an added advantage.

Strong Design/functional specification (CM, EM &Phases class) Experience & application development for recipes would be preferable.

Hands-on experience in FAT, SAT, commissioning, IQ, OQ and vendor coordination.

Familiarity with EPCM project execution models and engineering documentation workflows.

Supervisor responsibilities

Reporting lines

Automation Projects Manager

Candidate profile

Experience executing automation and batch automation projects in Pharmaceutical, API, or Biologics environments

Strong hands-on Experience in Process engineering, control and automation (PLC/DCS/SCADA).

Strong hands-on experience with Batch Manager, ISA-88/95 relevant industry standards.

Proven experience in FAT, SAT, Commissioning activities.

Proven experience in Batch recipe development, validation and qualification of batch lifecycle management.

Understanding of GMP, regulatory, and validation requirements in pharma manufacturing.

Software development & integration with MES/ERP.

Ability to troubleshoot complex automation issues.

Strong stakeholder communication, documentation, and leadership skills.

Key Delivery & Execution Priorities

The project is on a fixed and aggressive schedule — any slippage impacts plant readiness, validation, and product launch.

Managing multiple trackers/workstreams (Civil, MEP, Automation, Utilities, etc.) simultaneously without letting any critical path drift.

Requires strong forecasting capability — can't rely on reactive firefighting.

Must identify issues during design or procurement that may impact construction and commissioning months later.

Controlling scope creep in a dynamic project where new requirements or technical changes are frequent.

With timelines fixed, there’s a tendency for costs to escalate (e.g., fast-track changes, late procurement, vendor claims).

Language of job advertisement (English default)

English

Job Location - Patalganga MIDC (Near Panvel, Navi Mumbai)

Canteen Facility available

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