Senior Designer - Design for Manufacturability (DFM), PLM

Job Summary

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Mechatronics/Automation engineer

An equipment design/procurement group in the medical field of electrophysiology is looking for an experienced engineer that contributes to automation results for application in the manufacturing floor, is a hands-on solution generator that can effectively communicate ideas and concepts verbally and visually. Possesses automation machinery design experience and is familiar with medical-device manufacturing processes.

Is well versed and has experience in the robotics, mechatronics and/or automation fields.

Key Responsibilities

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Under limited supervision and in accordance with all applicable federal, state and local laws and regulations and Corporate Johnson & Johnson procedures and guidelines, this position:

• As assigned, completes mechatronics design solutions in timely manner, ensures project design meets intended requirements
• In consultation with senior engineers, ideate and execute on the design of automation equipment and robotics/automation hardware
• Makes use of advanced design and fabrication techniques, as well as the modification and extension of theories, precepts and practices of his/her branch, sciences and related disciplines
• Invents, designs and adapts robotics/automation solutions for complex handling and manufacturing challenges in the processing and assembly of medical devices
• In conjunction with project leader, is responsible for design, testing, installation and commissioning activities of robots and automation equipment
• Implements engineering solutions to complex material flow and human/machine efficiency problems throughout the catheter manufacturing plant
• Works with mechanical designers to complete automation design solutions making use of rapid prototyping and proof of concept solutions.
• Introduce automated processes into production, and train Maintenance and Production operators and technicians to maintain and troubleshoot the equipment after deployment into production
• Provides direction to Engineering Techs as necessary.
• Lay out and wire new industrial electrical control panels which are NFPA79/NEC/UL508A compliant, and create electrical, pneumatic schematics as required.
• As necessary, build electrical cabinet from the ground up, including field wiring, pneumatic and fluid connections to ancillary equipment, as required.
• Select and size electrical and electromechanical components (such as servos, stepper motors, AC motors, sensors (inductive, photosensors, magnetic)
• Select and source OTS (Off The Shelf) components to complete automation and robotic equipment
• Responsible for the creation of technical documents such as schematics, drawings, BOMs, test results, technical procedures, etc. for complete documentation of developed equipment
• Architect, write, and debug PLC language with an emphasis on generating code that is organized, structured, documented, maintainable and reusable.
• Program, implement software and troubleshoot software as required
• Leading and implementing capital projects involving robotics arms, DCS, SCADA or PLC system and HMI controls as applicable, for medical device process and assembly
• Implement (ANSI/RIA15.06/OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment.
• Generate aesthetically simple HMI screens for complex machinery while providing sufficient feedback for troubleshooting.
• Generate detailed user requirements for automation projects for purchasing of custom-made external vendors’ equipment
• Evaluate and apply new technology and innovation trends leading to the development of proof of concepts that end up in automation processes for the manufacturing floor
• Work safely and continually look for improvements in personnel and equipment safety, ensure safe design and operation of new equipment, ensure automation design reflects safety concerns for operations and maintenance.

Skill Requirements

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• Experience in the design of robotic arms and automation systems incorporating cameras or advanced optical sensing (e.g. structured light, active stereo, ToF depth sensors, LiDAR, laser illumination, HUDs or HMDs, light engines, etc.)
• Demonstrated excellence in programming PLCs. Must have a well-defined methodology for maintaining code structure and organization. Ability to program state-of-the-art machines for complex processes which involve multi-station parallel processing, pick and place automation, data acquisition, and PID control. Proven ability to design fault-tolerant systems with error handling and recovery.
• Proficiency selecting appropriate circuit protectors, wire and cable, sensors, safety hardware, PLC hardware, remote I/O, VFD and servo systems.
• Proficiency creating detailed electrical and fluid schematics
• Exposure to a wide variety of production machinery, industrial sensors, and equipment (Hydraulic, Motion control, LVDT and pressure transducers, dispense systems, temperature controllers, current and power meters, continuity and hi-pot testing, etc)
• Experience with Vision systems (Cognex, Keyence)
• Experience as a hands-on Controls Engineer or Equipment Engineer working on automation and/or electromechanical systems.
• Creation and adherence to URS (User Requirement specification) documents
• Experience with FAT and SAT
• Experience in automation industry standards
• Experience in applied mechanics, sensors, microcontrollers integration
• Knowledge of Automated Visual Inspection (AVI) or Image Analysis (IA)
• Demonstrated expertise in one or more automation platforms, preferable Rockwell Automation Systems.
• Significant experience and strong problem-solving skills in measurements, control (process and/or manufacturing), control systems, integration, and data.
• 4+ years of experience with complex automated material handling equipment, packaging technologies, and systems including robotics and high-speed manufacturing
• Demonstrated proficiency in process integration and electromechanical / mechatronic systems
• In depth knowledge of Electrical Standards (NFPA79, National Electric code, UL508A).
• In depth knowledge of Safety standards (ANSI/RIA15.06, OSHA).
• Advanced proficiency programming industrial equipment:
• Ladder logic PLCs (Allen Bradley ControlLogix, CompactLogix and RSLogix 5000, Studio 5000)
• Safety PLCs (Allen Bradley ControlLogix, SmartGuard)
• Human Machine Interface (HMI / GUI - AB Panelview, FactoryTalk, LabView, Ignition)
• Field bus Networks (AB DeviceNet, Ethernet IP, Safety rated field bus networks)
• Serial communication (RS-232) between PLCs and instruments
• Ethernet communications between machine PLCs and database systems

Must Have Skill

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Component Engineering,Design for Manufacturability (DFM),Product Life-Cycle Management

Good to Have Skill

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Other Requirements

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BS/MS Electrical Engineering, Mechatronics Engineering (or equivalent – Majors in: Controls and Computer Control Systems, Mechatronic Engineering, Automation Engineering, etc.)