Senior Automation Engineer (Warehouse & AMR)

Senior Automation Engineer (Warehouse & AMR) | Wilson, North Carolina Project: Major pharmaceutical manufacturing investment project involving automated warehousing, material handling and AMR integrationDuration: Inital 12month contract scope w/ extensionsWorking Arrangement: Primarily on-site, particularly during integration, commissioning and startup.Summary:Blackfield Associates are seeking an experienced Senior Automation Engineer to support the delivery of a hyper-scale pharmacetucial investment project in Wilson, North Carolina.The successful candidate will lead the integration and delivery of automated warehouse and material transport systems, combining AS/RS, WMS/WCS platforms, autonomous mobile robots (AMRs) and manufacturing equipment.Working alongside Manufacturing, Warehouse Operations, IT/OT, Quality and external suppliers, you will take technical ownership of system interfaces and controls, ensuring safe, reliable and efficient material movement within a cGMP manufacturing environment.This is an excellent opportunity to play a key role in delivering a complex automation project from design through commissioning and operational handover.Key Responsibilities:Develop automation requirements, functional specifications, controls architecture and system interface specifications.Lead integration across WMS, WCS, AS/RS, AMR fleet management and manufacturing systems, including SAP EWM and MES.Develop and troubleshoot PLC/HMI applications, equipment interfaces, handshakes, permissives and interlocks.Integrate conveyors, transfer stations, pallet washers, automatic doors and material airlocks.Configure and optimise AMR fleet operations, including mission priorities, traffic management, docking and charging strategies.Develop recovery strategies for communication failures, equipment faults, failed transfers and safety stops.Lead FAT, SAT, integrated commissioning and startup activities.Support qualification and computer system validation (CSV), ensuring traceable requirements and documented test evidence.Validate throughput, fleet capacity and critical material delivery requirements alongside simulation and operations teams.Collaborate with IT/OT and safety teams on network connectivity, cybersecurity and safe operating practices.Coordinate suppliers, resolve integration challenges and maintain technical documentation.Provide post-startup support, root cause analysis and continuous system improvement.Required Technical Expertise:Industrial automation, PLC/HMI development and controls engineering.Automated material handling systems, including AS/RS and conveyors.AMR/AGV integration and fleet management systems.WMS/WCS platforms and manufacturing system integration.Industrial communication protocols, including APIs, OPC UA and Industrial Ethernet.PLC-controlled equipment integration, electrical drawings and interlocks.FAT, SAT, commissioning, troubleshooting and system handover.Functional specifications, test protocols and system validation.Candidate Profile:Bachelor's degree in Electrical Engineering, Automation, Controls, Mechatronics, Computer Engineering or a related discipline.Minimum five years' industrial automation or controls engineering.Proven experience integrating automated warehouse or material handling systems, including AMR/AGV and PLC-controlled equipment.Hands-on PLC/HMI development and troubleshooting experience.Experience integrating multiple automation platforms, software systems and equipment suppliers.Knowledge of industrial communications, commissioning and startup.Experience with FAT, SAT, validation and controlled documentation.Strong technical coordination and stakeholder management skills.Desirable Experience:Pharmaceutical or biotechnology manufacturing, including cGMP, CQV and CSV.SAP EWM, MES, WMS/WCS and automated warehouse integration.Siemens or Rockwell PLCs, SCADA, SQL or scripting.AMR fleet deployment, traffic management and simulation.Cleanroom material transfers, cold-chain requirements and IT/OT cybersecurity.