Senior Staff Automation Engineer (Onsite - Acton, MA)

Position Overview: 
Insulet is the world’s leading manufacturer of high-volume, disposable, electromechanical, wearable medical devices.  As a Sr. Staff Automation Engineer in the Global Equipment Engineering Group, the candidate will support both current manufacturing operations as well as new product development by providing expertise related to the continuous improvement efforts for existing manufacturing processes/equipment.  The candidate will also work with internal customers and external vendors to specify, procure, and install new manufacturing lines and equipment in accordance with business needs.  The candidate is expected to be a highly experienced technical leader responsible for bridging execution-level engineering and system-level automation strategy across global manufacturing operations. 

This role expands beyond individual project execution to include driving standardization, influencing equipment architecture, and leading complex, multi-line automation initiatives. The Senior Staff Engineer partners closely with cross-functional teams and external suppliers to deliver scalable, high-performance manufacturing solutions while mentoring engineers and strengthening organizational capability. 

This position is suited for a hands-on technical expert who can operate independently, lead without authority, and translate business needs into robust automation systems. This role is suitable for an energetic problem solver who has solid technical, organizational and communication skills. 

Responsibilities: 

The successful candidate will primarily focus on the design, development, specification and implementation of automated equipment for assembly and packaging processes.  In addition, continuous improvement efforts, obsolescence programs, technology transfers and new product development may also be exercised in support of business objectives.  Important job qualifications include: 

• Lead and oversee the specification, selection, manufacturing acceptance, installation, startup, commissioning, and validation of fully automated and advanced discrete component assembly and/or packaging systems. 

• Provide system-level technical leadership to ensure solutions meet performance, scalability, reliability, and cost targets across programs and sites. 

• Serve as a recognized subject matter expert in mechanical engineering, demonstrating expert-level machine design capability and deep knowledge of automated assembly and packaging systems. 

• Demonstrated advanced technical expertise and subject matter leadership in mechanical engineering, including assembly and packaging technologies (e.g., blister forming, cartoning, bagging, sealing). 

• Drive standardization and advancement of core technologies across programs and sites. Technical mastery in the following areas is sought: 

• Provide technical direction and design oversight for machine design including pneumatics, linkage design, mechatronics, robotics, and drive systems. 

• Process technologies: ultrasonic welding, heat transfer decoration, hot stamping, laser welding, laser decoration. 

• Packaging: material knowledge, cartoning, conveyor systems and sealing technologies. 

• Lead the end-to-end development of automation solutions, translating complex product and manufacturing requirements into scalable, multi-line or multi-site automation strategies. 

• Define and evaluate system architectures, technical tradeoffs, and capital investment strategies, ensuring alignment with business objectives. 

• Drive solutions that balance performance, cost, risk, and regulatory requirements. 

• Own and drive strategic supplier engagement, including specification development, design reviews, and performance management. Lead complex, multi-workstream projects, ensuring alignment to scope, cost, schedule, and performance objectives while driving accountability across internal teams and external partners. 

• Provide oversight and strategic direction for validation activities (FAT, SAT, IQ/OQ/PQ), ensuring consistency, compliance, and effective risk mitigation across programs and sites. 

• Serve as a technical leader and mentor, developing engineering capability across the organization. Drive improvements in engineering processes, standards, and best practices, including development of training, SOPs, and design guidelines. 

• Lead resolution of complex, system-level technical challenges, effectively navigating barriers across internal manufacturing operations and external equipment suppliers. Operate across global, cross-functional teams, influencing outcomes and driving alignment. Communicate effectively at both technical and leadership levels. 

• Ensure integration of machine safety, regulatory compliance, and global standards into equipment and system design strategies. Drive consistent application of safety and compliance requirements (CE, UL, SCCR, NFPA-70E/79, ISO, etc.) across programs and suppliers. 

• Contribute to equipment platform strategies, technology roadmaps, and cross-site standardization efforts to enable scalable and sustainable manufacturing solutions. 

Preferred Requirements: 

• Bachelor of Science in Mechanical Engineering.  Master of Science in Mechanical Engineering is a plus. 

• 10-13+ years of hands-on machine design experience. 

• Proven experience leading large-scale or multi-line automation programs 

• Experience supporting global manufacturing or multi-site deployments 

• Experience in regulated industries (medical device strongly preferred) 

Preferred Skills and Competencies: 

• Demonstrated ability to influence technical direction, establish best practices, and drive standardization across teams or sites. 

• Demonstrated flexibility and ability to function in a fast-paced, growth-oriented environment, adapting to changing priorities while maintaining focus on strategic objectives. 

• Strong organizational and program management skills, with the ability to manage multiple complex initiatives and prioritize across competing demands. 

• Highly effective interpersonal skills with the ability to influence and collaborate across cross-functional and global teams. 

• Excellent communication skills (verbal and written), with the ability to clearly convey complex technical concepts to engineering teams, cross-functional partners, and senior leadership. 

• Advanced proficiency with structured problem-solving methodologies, with the ability to lead resolution of complex, system-level technical challenges. 

• Demonstrated success leading and contributing to high-performing, cross-functional teams, driving alignment and delivering results in a collaborative environment. 

• Strong proficiency in common engineering and business tools (e.g., spreadsheets, presentations, data systems) with the ability to leverage tools to support decision-making. 

• Proficiency with the use of CAD modelling software (SolidWorks preferred). 

• Working knowledge of Minitab and/or JMP statistical analysis software. 

• Demonstrated experience leveraging data analysis to drive insights, prioritize initiatives, and improve equipment and process performance. 

Physical Requirements:  

• The successful candidate must be able to travel domestically and internationally as business needs demand. Travel is estimated at 30% max.  

• The successful candidate will perform other duties as required.