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 Lilly’s 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 Lilly’s 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