Senior Automation Engineer (DeltaV & Syncade), Limerick

Position Summary

Horizon Controls Group is seeking an experienced Senior Automation Engineer with strong hands-on expertise in both Emerson DeltaV and Werum PAS-X Syncade systems to support and enhance pharmaceutical manufacturing operations in Limerick, Ireland.

The successful candidate will play a critical role in the design, implementation, validation, optimization, and lifecycle management of automation and MES platforms supporting GMP-regulated production environments. This role requires deep technical knowledge of process control systems, manufacturing execution systems, integration architecture, and pharmaceutical compliance standards.

This position is ideal for a professional who has successfully delivered automation and digital manufacturing projects within biotech or pharmaceutical manufacturing facilities and possesses strong collaboration skills across engineering, operations, quality, validation, and IT teams.

Key Responsibilities

DeltaV Automation Responsibilities

• Design, configure, implement, and maintain Emerson DeltaV DCS/PCS systems for pharmaceutical manufacturing processes.
  
• Develop and modify:
  
  • Control modules
    
  • Equipment modules
    
  • Batch recipes
    
  • Phases and operations
    
  • Alarms and interlocks
    
  • HMI graphics
    
• Support commissioning, startup, SAT, FAT, and qualification activities.
  
• Troubleshoot DeltaV hardware and software issues in manufacturing environments.
  
• Perform system upgrades, patches, migrations, and lifecycle management activities.
  
• Configure and maintain:
  
  • DeltaV Batch
    
  • DeltaV Continuous Historian
    
  • DeltaV Live
    
  • OPC interfaces
    
  • SIS/ESD integrations where applicable
    
• Ensure high system availability and cybersecurity compliance.
  
• Participate in root cause investigations and CAPA implementation for automation-related deviations.
  

Syncade MES Responsibilities

• Configure and support Werum PAS-X Syncade MES applications within GMP production operations.
  
• Develop and maintain:
  
  • Electronic Batch Records (EBR)
    
  • Workflows
    
  • Material management processes
    
  • Weigh & dispense solutions
    
  • Equipment tracking
    
  • Recipe execution flows
    
• Collaborate with manufacturing and quality teams to optimize MES-driven workflows.
  
• Integrate Syncade with:
  
  • DeltaV
    
  • SAP/ERP systems
    
  • LIMS
    
  • Historians and data platforms
    
• Support electronic review-by-exception initiatives.
  
• Drive digital manufacturing and paperless manufacturing transformation programs.
  
• Troubleshoot MES execution issues and support manufacturing operations during production campaigns.
  

System Integration Responsibilities

• Develop and maintain integrations between DeltaV and Syncade platforms.
  
• Support ISA-88 and ISA-95 aligned automation architectures.
  
• Collaborate with IT/OT teams on:
  
  • Network architecture
    
  • Data integrity
    
  • Cybersecurity
    
  • System interoperability
    
• Ensure compliant data flow between automation layers and enterprise systems.
  
• Support serialisation, track-and-trace, and digital manufacturing initiatives where applicable.
  

Validation & Compliance

• Ensure systems comply with:
  
  • GMP/GxP requirements
    
  • FDA 21 CFR Part 11
    
  • Annex 11
    
  • Data Integrity standards
    
• Author and review:
  
  • URS
    
  • FS/DS
    
  • IQ/OQ/PQ protocols
    
  • Risk assessments
    
  • Traceability matrices
    
  • SOPs
    
• Participate in audits and regulatory inspections.
  
• Maintain validated state of automation and MES systems.
  

Required Qualifications

Education

• Bachelor’s or Master’s degree in:
  
  • Automation Engineering
    
  • Electrical Engineering
    
  • Computer Engineering
    
  • Chemical Engineering
    
  • Biotechnology Engineering
    
  • Other related technical discipline
    

Mandatory Technical Experience

DeltaV (Required)

• Minimum 5+ years of hands-on Emerson DeltaV experience.
  
• Strong experience with:
  
  • DeltaV Batch
    
  • Recipe configuration
    
  • Control strategies
    
  • Commissioning and troubleshooting
    
  • System administration
    
• Experience in GMP pharmaceutical or biotech manufacturing environments.
  

Syncade MES (Required)

• Minimum 3+ years of hands-on Syncade MES experience.
  
• Experience configuring and supporting:
  
  • Electronic Batch Records
    
  • Workflow management
    
  • Manufacturing execution processes
    
  • Recipe execution
    
• Strong MES integration experience with DeltaV.
  

Candidates must possess strong practical experience in BOTH DeltaV and Syncade. Experience in only one platform will not meet the requirements for this role.

Preferred Qualifications

• Experience in sterile, biologics, API, or fill-finish manufacturing environments.
  
• Knowledge of:
  
  • ISA-88
    
  • ISA-95
    
  • OPC/OPC UA
    
  • SQL databases
    
  • Historian systems
    
  • Industrial networking
    
• Experience with:
  
  • Emerson Lifecycle Services
    
  • PAS-X integrations
    
  • SAP integration
    
  • Serialization systems
    
  • Digital transformation projects
    
• Exposure to cloud manufacturing analytics platforms is advantageous.
  
• PMP, DeltaV, or MES certifications are a plus.