Senior Rockwell PLC Automation Engineer

Job Summary

Horizon Controls Group is seeking experienced Senior Rockwell PLC / Automation Engineers to support the design development and delivery of advanced manufacturing automation systems within a highly regulated pharmaceutical environment.

This position is focused on engineers with strong design-level automation expertise rather than execution-only experience. The successful candidate will play a key role in architecting and developing automation solutions for complex manufacturing systems working within Lillys proprietary automation environment rather than traditional off-the-shelf SCADA platforms such as Ignition PlantPAx or DeltaV.

The role requires a highly technical and adaptable automation professional capable of working closely with global engineering process manufacturing CQV and digital teams to deliver scalable compliant and high-performing automation solutions supporting next-generation pharmaceutical manufacturing.

Key Responsibilities

• Lead the design and development of Rockwell PLC-based automation solutions for pharmaceutical manufacturing systems and equipment.
  
• Develop and modify PLC logic control strategies functional specifications and automation architectures within Lillys proprietary automation framework.
  
• Support automation system lifecycle activities including design reviews testing commissioning support troubleshooting and operational readiness.
  
• Collaborate with process engineers manufacturing teams CQV MES and digital engineering functions to ensure automation solutions align with operational and compliance requirements.
  
• Work within a non-standard Lilly automation architecture requiring flexibility and the ability to quickly understand custom-built manufacturing control systems.
  
• Participate in automation design workshops risk assessments and technical reviews to ensure robust and scalable system designs.
  
• Support integration activities between PLC systems MES platforms historians databases and enterprise systems.
  
• Develop and review technical documentation including URS FDS SDS IO lists network architecture diagrams test documentation and change controls.
  
• Ensure compliance with GMP GAMP5 data integrity and cybersecurity standards throughout the automation lifecycle.
  
• Provide technical leadership and mentorship to junior engineers and project teams.
  
• Support FAT SAT commissioning IQ/OQ activities and startup support where required.
  
• Troubleshoot complex automation and controls issues within live manufacturing environments.
  

Requirements

Required Experience & Qualifications

• Degree in Automation Electrical Electronic Mechatronic Software or related Engineering discipline.
  
• Strong experience as a PLC / Automation Engineer within pharmaceutical biotech or regulated manufacturing industries.
  
• Advanced hands-on expertise with Rockwell PLC platforms including ControlLogix CompactLogix Studio 5000 FactoryTalk and related technologies.
  
• Proven design-level experience developing automation architectures PLC code and control strategies not solely commissioning or execution support.
  
• Comfortable working within custom or proprietary automation architectures rather than relying exclusively on standard SCADA platforms such as Ignition PlantPAx or DeltaV.
  
• Strong understanding of industrial automation networks field instrumentation and system integration principles.
  
• Experience supporting manufacturing process equipment and automated production systems.
  
• Familiarity with GMP environments GAMP5 ISA-88 ISA-95 and pharmaceutical validation requirements.
  
• Experience with automation testing commissioning and qualification activities.
  
• Strong problem-solving and analytical skills in complex operational environments.
  

Preferred Experience

• Experience within API biologics or advanced pharmaceutical manufacturing environments.
  
• Exposure to MES integration digital manufacturing or Industry 4.0 initiatives.
  
• Knowledge of serialization batch systems or data historians.
  
• Experience working on large-scale greenfield pharmaceutical projects.
  
• Familiarity with cybersecurity and OT network standards.
  

Key Competencies

• Automation system design and architecture expertise
  
• Strong technical leadership and ownership mindset
  
• Excellent collaboration and communication skills
  
• Adaptability within custom engineering environments
  
• High attention to quality compliance and detail
  
• Strong troubleshooting and root cause analysis capabilities