Sr. Automation Engineer; Onsite - Acton, MA

Job Summary

Thie Sr. Staff Automation Engineer role is a senior technical position focused on leading automation strategy, equipment design, and large-scale manufacturing initiatives across Insulet's global operations. The role oversees development and deployment of advanced automated assembly and packaging systems, drives standardization and continuous improvement, partners with suppliers and cross‑functional teams, and mentors engineers while ensuring scalable, compliant, and high‑performing manufacturing solutions.

Candidates should have 10+ years of machine design and automation experience, ideally within the medical device industry.

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 and 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.

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. It is suitable for an energetic problem solver who has solid technical, organizational, and communication skills.

• 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