Sr. Automation Engineer (Onsite)

AbbVie - Irvine, CA

Full-time - Mid Level

Irvine, CA

Chemical Manufacturing

About the position

The Senior Automation Engineer at AbbVie plays a crucial role in supporting the manufacturing process, utilities, and Facilities Control Systems. This position involves complex configuration and programming of Operation Technology (OT) Systems in accordance with AbbVie’s change management procedures. The engineer will provide technical support and troubleshoot systems and areas assigned to them, ensuring that all operations run smoothly and efficiently. Additionally, the role encompasses the administration and maintenance of assigned OT systems, adhering to departmental procedures to maintain compliance and operational integrity. As a Subject Matter Expert (SME) for Automation Applications and Process Control systems, the Senior Automation Engineer will offer insights and recommendations regarding manufacturing operation continuance issues and process improvements. The engineer will be responsible for performing or reviewing configuration and programming tasks, ensuring that all practices align with user and functional requirements. Training for OT Systems Users and Engineers in new automation technologies and process control applications is also a key responsibility of this role. The engineer will diagnose and troubleshoot OT System hardware, software, and networking issues, replacing defective components as necessary. They will implement and validate OT systems upgrades and data migrations for Distributed Control Systems (DCS), Programmable Logic Controllers (PLCs), SCADA, and Data Historian systems. Supporting the OT Systems lifecycle, the engineer will develop and execute qualification protocols and maintain associated documentation, including System Functional and Design Specifications. Scheduled administration and maintenance tasks will include operating systems and anti-virus updates, user account management, and critical data backups. The engineer will establish project management techniques to monitor, report, and control automation projects, supporting Capital projects when automation expertise is required. Flexibility in work schedule is essential, as the engineer may need to perform maintenance and system changes during off-peak hours, which could involve overtime, overnight shifts, or weekend work. Compliance with EHS management system requirements and obligations is paramount, promoting continuous improvement while considering EHS aspects during design and change processes. The engineer must adhere to all EHS procedures and policies, including incident reporting and waste management, ensuring a safe and compliant working environment.

Responsibilities

• Acts as Subject Matter Expert (SME) for Automation Applications and Process Control systems.
• Provides process controls inputs and recommendations regarding manufacturing operation continuance issues and process improvements.
• Perform or review configuration and programming using defined practices to establish compliance with users and functional requirements.
• Provides training for OT Systems Users/Engineers in new automation technologies and process control applications.
• Diagnose and troubleshoot OT System hardware, software, and networking issues, replacing defective components as needed.
• Responsible for implementing and validating OT systems upgrades and data migrations for DCS, PLC's, SCADA, and Data Historian systems.
• Support OT Systems lifecycle including validation activities by developing and executing qualification protocols plus associated documentation like System Functional and Design Specifications.
• Perform scheduled OT Systems administration and maintenance tasks such as operating systems (OS) and anti-virus updates, user accounts management, critical data back-up and others.
• Establish project management techniques in monitoring, reporting, and controlling automation projects according to size and criticality (small to medium projects).
• Support Capital projects when automation expertise is required.
• Work schedule flexibility to perform or support maintenance works and other changes to systems in production during off-peak hours.

Requirements

• Bachelor's degree in Computer Science, Engineering, or related discipline with a minimum of six (6) years of relevant experience required.
• Master's degree in Computer Science, Engineering, or related discipline with a minimum of four (4) years of relevant experience is a plus.
• Working experience administering and/or configuring of Distributed Control Systems (DCS) such as Emerson DeltaV, Foxboro I/A, is required.
• Working experience with SCADA and PLCs (such as Allen-Bradley ControlLogix), programming in ladder logic and instructional texts.
• Experience with commissioning and qualification activities, including computerized systems validation.
• Experience administering and/or configuring a data historian system such as OSIsoft PI is a plus.
• Solid understanding of pharmaceutical and biotechnology manufacturing processes, including operational best practices and regulatory expectations.
• Industry experience exposure to FDA, GMP, 21CFR11, Data Integrity, Safety and Environmental legislation.
• Experience designing and implementing Windows Server Operating Systems and related components including Active Directory, NTFS Setup and Security, User Administration, TCP/IP with DHCP, WINS and DNS would be a plus.

Nice-to-haves

• HMI graphics development and management would be a plus.
• Experience with select agents and toxins access in biosafety level 2 and 3 laboratories.