Job Title: PLC Automation Engineer
Role Overview
The PLC Automation Engineer will support the design,
development, commissioning, and lifecycle management of automated systems
within a GMP-regulated pharmaceutical manufacturing environment. The role
involves hands-on PLC programming, system integration, troubleshooting, and
collaboration with cross-functional teams to ensure safe, compliant, and
reliable operation of production and utility systems.
Key Responsibilities:
- Design,
develop, modify, and maintain PLC control systems supporting
pharmaceutical manufacturing, packaging, utilities, and process equipment.
- Program
and troubleshoot PLCs (e.g. Rockwell Allen-Bradley, Siemens, Schneider),
including development of ladder logic, function block diagrams, and
structured text as applicable.
- Support
automation commissioning activities, including FAT, SAT, and on-site
start-up, ensuring systems meet functional and GMP requirements.
- Interface
PLC systems with SCADA/HMI platforms (e.g. FactoryTalk, WinCC, iFIX),
ensuring clear operator interfaces and alarm management.
- Interpret
and work from P&IDs, control philosophies, functional specifications,
and electrical drawings.
- Provide
automation support for manufacturing equipment, process skids, packaging
lines, utilities (HVAC, WFI, clean steam), and ancillary systems.
- Participate
in change control, deviation investigations, and root cause analysis
related to automation systems.
- Support
Computer System Validation (CSV) activities, including IQ/OQ testing,
protocol execution, traceability, and documentation reviews in line with
GAMP 5.
- Ensure
automation systems comply with GMP, data integrity (ALCOA+), and site
quality standards.
- Collaborate
with Engineering, QA, Manufacturing, Maintenance, IT, and external vendors
to deliver projects and resolve technical issues.
- Provide
ongoing troubleshooting and operational support to minimise downtime and
improve system reliability.
- Contribute
to continuous improvement initiatives, standardisation, and automation
best practices across the site.
Required Skills & Experience:
- Degree
in Automation Engineering, Electrical Engineering, Instrumentation, or
related discipline.
- Proven
experience as a PLC Automation Engineer in a pharmaceutical, biotech, or
regulated manufacturing environment.
- Strong
hands-on experience with PLC programming, ideally Allen-Bradley / Rockwell
systems.
- Experience
with SCADA/HMI systems and industrial networks (Ethernet/IP, Profinet,
Modbus).
- Solid
understanding of GMP environments, regulated change management, and
validation principles.
- Ability
to read and interpret P&IDs, control narratives, and electrical
schematics.
- Experience
supporting FAT, SAT, commissioning, and start-up activities.
- Strong
troubleshooting, analytical, and problem-solving skills.
- Excellent
communication skills and ability to work effectively within
cross-functional teams.
Desirable / Nice-to-Have:
- Experience
with DeltaV, PCS7, or DCS systems.
- Exposure
to CSV documentation (URS, FS, IQ, OQ, traceability matrices).
- Knowledge
of process equipment automation (bioreactors, CIP/SIP, fillers,
packaging).
- Experience
working on Irish or EU pharma sites.
- Familiarity
with alarm management standards (ISA-18.2 / EEMUA 191).
Skills Required
- Degree in Automation Engineering, Electrical Engineering, Instrumentation, or related discipline
- Proven experience as a PLC Automation Engineer in a pharmaceutical, biotech, or regulated manufacturing environment
- Hands-on PLC programming experience, ideally Allen-Bradley / Rockwell systems
- Experience with SCADA/HMI systems (FactoryTalk, WinCC, iFIX) and industrial networks (Ethernet/IP, Profinet, Modbus)
- Solid understanding of GMP environments, regulated change management, and validation principles
- Ability to read and interpret P&IDs, control narratives, and electrical schematics
- Experience supporting FAT, SAT, commissioning, and start-up activities
- Strong troubleshooting, analytical, and problem-solving skills
- Excellent communication skills and ability to work within cross-functional teams
- Experience with DeltaV, PCS7, or DCS systems
- Exposure to CSV documentation (URS, FS, IQ, OQ, traceability matrices)
- Knowledge of process equipment automation (bioreactors, CIP/SIP, fillers, packaging)
- Experience working on Irish or EU pharma sites
- Familiarity with alarm management standards (ISA-18.2 / EEMUA 191)
What We Do
Horizon Controls Group: A global leader in automation consulting, enabling both clients and employees to live on the forefront of evolving technology. Horizon Controls Group is a modern, global technology company, specializing in automation consulting, engineering, and training. Founded on the belief that our people are the difference, we have grown entirely from customer references and successive projects. Our people and their established reputation are our most valued assets. This belief has created a great place to work, enabling us to attract the very best and to give our customers confidence in our superior solutions. Our business is comprised of excellence at every level. We employ a pro-active and comprehensive approach to projects -- asking the right questions, analyzing client needs, and engineering a skilled solution. We are committed to understanding the entire spectrum of your automation challenges and to developing uniquely tailored innovative solutions. Our decision to be vendor-independent enables us to offer tailored solutions and represent your needs free of any conflict of interest. We are aligned exclusively with our customers' goals and system requirements, enabling us to provide maximum value. Ultimately, the ability to harvest maximum value from new systems is dependent on the quality and training of your people. Just as we expect and ensure absolute expertise in our people, we work with you to ensure your team is trained to the specific needs of your organization and remain at the forefront of industry trends. We are a global company operating in the United States from our headquarters in Blue Bell, PA and offices in Indiana, Massachusetts, North Carolina, and California and from Cork in Ireland. This is Horizon Controls Group’s official company LinkedIn page.
