Sr. Automation Engineer - Mechanical

Primary Function of Position

Contribute your technical manufacturing, equipment design, automation, and project management skills to a dynamic team creating high-volume automated assembly lines for precision instruments and accessories used in minimally invasive robotic surgery. The role spans evaluation, maintenance, repair, design, analysis, and continuous improvement of mechanical/electronic equipment; close collaboration with machine integrators through specification, design, build, commissioning, and validation; and ongoing production support across sites.

Essential Job Duties

• Lead creation of automation line specifications; source, evaluate, and manage equipment suppliers and machine integrators through design, build, FAT/SAT, and shipment.
• Design, document, procure, qualify, implement, and improve fixtures, tools, and equipment for high-volume assembly.
• Provide daily production line support; resolve emergency/unscheduled problems and repairs to ensure equipment uptime and availability.
• Develop and execute validation protocols (IQ/OQ/DQ/PQ and PPQ) for equipment and automated assembly lines; maintain compliant records.
• Determine and analyze equipment performance trends; define and implement improvements to maintainability, reliability, availability, cycle time, capacity, and first-pass yield.
• Perform and/or support PFMEA for accessories manufacturing lines; incorporate and validate critical tests used in manufacturing.
• Provide DFx input (Manufacturing, Assembly, Automation, Reliability) to design teams; ensure consistency/commonality of hardware and standard part selections.
• Integrate mechatronics components (sensors, motors, pneumatics), motion/vision control, and PLC-based line controls; support robot programming where applicable.
• Create and maintain controlled documentation including BOMs, workflow processes, manufacturing plans, and detailed work instructions; review peer edits.
• Teach, mentor, and train technicians/engineers in specialized equipment: diagnosing, repairing, maintaining, calibrating; improve installation, repair, and upkeep documentation.
• Conduct SAP transactions relevant to process/equipment operations; plan resources and budgets for product/process improvements, tooling, and testing.
• Identify and implement continuous improvement projects for product reliability and cost reduction; proactively seek technologies to improve production processes.
• Support inter-site collaboration (e.g., suppliers and Mexicali plant) and periodic travel.

Required Skills and Experience

• Strong communication skills to interface cross-functionally with technicians, product development, planning, purchasing, regulatory, inspection, customer support, and clinical marketing.
• Strong analytical and troubleshooting skills for complex electro-mechanical/laser/vision system equipment.
• Experience with automated line controls (PLC, I/O components), motion/vision control, and mechatronics integration.
• CAD proficiency (SolidWorks preferred); blueprint reading and interpretation; GD&T and tolerance stack analysis.
• Experience managing product/process changes and executing equipment/process validation.
• Organizational skills to manage fast-paced projects simultaneously; prior technical writing experience.
• Experienced with ISO 13485/9001 medical device manufacturing environments.

Required Education and Training

• BS/MS degree in Mechanical, Electrical/Electronics, Mechatronics, Manufacturing Engineering, or equivalent.
• 8+ years' experience as a design/manufacturing/equipment engineer supporting products with significant mechanical/electromechanical content.

Working Conditions

Onsite role with periodic travel; may require occasional weekend shift support during commissioning or urgent repairs.

Preferred Skills and Experience

• Experience designing automated equipment and complex mechanisms; robotics programming exposure.
• Knowledge of manufacturing processes: machining, injection molding, transfer molding, MIM, crimping, ultrasonic/laser welding, optical testing, fiber routing.
• Experience with high-volume automated assembly of plastic forming/joining processes.
• Leadership experience or a background in cross-functional team coordination.
• Spanish language proficiency; ability to travel to suppliers and other Intuitive facilities.