Senior Manufacturing Engineer, Test & Controls

Senior Manufacturing Engineer

The Senior Manufacturing Engineer, Test & Controls is a hands-on technical contributor responsible for developing, validating, and optimizing manufacturing test systems and processes for next-generation medical devices. This role emphasizes test development for low-power embedded electronics and analog/digital circuits, supporting pilot and production environments with robust, scalable, and compliant solutions.

The engineer will collaborate cross-functionally with R&D (Electrical/Mechanical), Manufacturing, Software, Quality, and Systems teams to ensure test strategies align with product requirements and manufacturing capabilities.

Note: This role will begin with a 3 to 6-month rotation through Insulet's Global Manufacturing Engineering (GME) organization. During this time, the engineer will gain hands-on experience across multiple teams, build cross-functional relationships, and develop a strong understanding of Omnipod assembly and system-level function. After the rotation period, the engineer will transition into a dedicated NPI project team.

Responsibilities

• Develop and implement manufacturing test strategies for pilot and production lines, focusing on low-power embedded systems and analog/digital circuits.
• Design, source, and validate custom test fixtures and automated test systems.
• Collaborate with Electrical Engineering to define test requirements and ensure design for testability (DFT).
• Author and execute test protocols and validation documentation, including Installation Qualification (IQ), Operational Qualification (OQ), Performance Qualification (PQ), Test Method Validation (TMV), in compliance with FDA regulations and ISO 13485 standards.
• Troubleshoot and resolve test-related issues on the manufacturing floor, including product hardware, software, and test system performance.
• Support process verification, validation, and documentation for new and existing products.
• Apply principles of electrical and system design to analyze failures and drive improvements in test and manufacturing processes.
• Support risk management, usability studies, and design validation processes.
• Interface with internal and external resources to source and qualify test equipment and components.
• Leverage data to drive problem resolution and continuous improvement.
• Support integration of data collection systems for quality, productivity, and traceability.

Key Decision Rights

• Technical lead for new product manufacturing test strategy, design, setup, validation, and equipment/vendor selection.
• Influence manufacturing test development and capacity expansion planning.

Required Leadership/Interpersonal Skills & Behaviors

• Strong communicator with the ability to collaborate effectively across engineering and manufacturing teams.
• Demonstrated ability to make sound, data-driven decisions in fast-paced environments.
• Proactive in identifying and implementing process and test improvements.
• Skilled at balancing multiple priorities and managing cross-functional projects.
• Maintains focus, adaptability, and resilience in hands-on technical settings.

Required Skills and Competencies

• Proficiency in analog and digital circuit design, low-power embedded systems, and PCB layout principles.
• Strong experience with LabVIEW or similar test automation platforms.
• Familiarity with electrical engineering tools and instruments (oscilloscopes, multimeters, power analyzers, etc.).
• Experience developing and validating electrical test systems and fixtures.
• Working knowledge of FDA design control guidelines and medical device regulatory requirements.
• Experience with design verification, risk management, and usability testing.
• Understanding of electrical safety and EMC standards for medical devices.
• Familiarity with servo drives, motion control, and industrial automation is a plus.
• Experience in testing wireless communication technologies (e.g., RF, BLE) and signal processing is a plus.
• Experience with SQL Server, Visual Basic, and networked data collection systems is a plus.

Education and Experience

• BS in Electrical, Software, or Manufacturing Engineering with 7+ years of experience in medical device or other highly regulated manufacturing environment, or MS with 5+ years of experience.
• Experience with Class II medical devices and cleanroom manufacturing environments is highly desirable.

Additional Information

• Able to work in a Class 8 Cleanroom Environment.
• Role is based in Acton and the ideal candidate will be in office 4+ days a week.
• Travel up to 10%, including international travel to suppliers and manufacturing sites.
• NOTE: This position is eligible for hybrid working arrangements (requires on-site work from an Insulet office at least 1x/week; may work remotely other days).

The US base salary range for this full-time position is $92,400.00 - $138,600.00. Our salary ranges are determined by role, level, and location. The range displayed on each job posting reflects the minimum and maximum target for new hire salaries for the position in the primary work location in the US. Within the range, individual pay is determined by work location and additional factors, including job-related skills, experience, and relevant education or training. Your Talent Acquisition Specialist can share more about the specific salary range for your preferred location during the hiring process. Please note that the compensation details listed in US role postings reflect the base salary only, and do not include bonus, equity, or benefits.

Insulet Corporation (NASDAQ: PODD), headquartered in Massachusetts, is an innovative medical device company dedicated to simplifying life for people with diabetes and other conditions through its Omnipod product platform. The Omnipod Insulin Management System provides a unique alternative to traditional insulin delivery methods. With its simple, wearable design, the tubeless disposable Pod provides up to three days of non-stop insulin delivery, without the need to see or handle a needle. Insulet's flagship innovation, the Omnipod 5 Automated Insulin Delivery System, integrates with a continuous glucose monitor to manage blood sugar with no multiple daily injections, zero fingersticks, and can be controlled by a compatible personal smartphone in the U.S. or by the Omnipod 5 Controller. Insulet also leverages the unique design of its Pod by tailoring its Omnipod technology platform for the delivery of non-insulin subcutaneous drugs across other therapeutic areas.

At Insulet Corporation all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.