Sr. Staff Automation Engineer

About the Role The Sr. Staff Automation Engineer is a senior technical leadership role focused on defining automation strategy, equipment design, and large-scale manufacturing initiatives across Insulet’s global operations. The role oversees development and deployment of automated assembly and packaging systems, drives standardization and continuous improvement, partners with suppliers and cross-functional teams, and mentors engineers to deliver scalable, compliant manufacturing solutions. What You'll Do

• Lead specification, selection, manufacturing acceptance, installation, startup, commissioning, and validation of automated assembly and/or packaging systems.
• Provide system-level technical leadership to ensure performance, scalability, reliability, and cost targets across programs and sites.
• Serve as a recognized subject matter expert in mechanical engineering, with deep knowledge of automated assembly and packaging systems.
• Drive standardization and advancement of core technologies across programs and sites.
• Lead 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.
• Own 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. What We're Looking For
• 10+ years of machine design and automation experience, ideally within the medical device industry.
• Demonstrated advanced technical expertise in mechanical engineering, including assembly and packaging technologies (e.g., blister forming, cartoning, bagging, sealing).
• Technical mastery in machine design domains: 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.
• Proven experience translating product and manufacturing requirements into scalable automation strategies, and leading multi-site programs.
• Strong supplier engagement and cross-functional collaboration skills, with project management experience.
• Familiarity with validation activities (FAT, SAT, IQ/OQ/PQ) and regulatory/compliance considerations.
• Excellent communication and leadership abilities, capable of influencing global teams. Nice to Have
• Experience leading multi-site/global automation initiatives.
• Ability to operate independently and lead without formal authority.
• Experience bridging execution-level engineering and system-level automation strategy. Compensation & Benefits
• Salary and benefits not disclosed in the posting.