Michael Cawley discusses the crucial and unexpected skills he applies in his day-to-day role at Abbott.
A controls engineer at pharmaceutical Abbott, Michael Cawley, who is based in Donegal, works on the production of FreeStyle Libre continuous monitors.
“A device I also use myself as I have T1 diabetes,” Cawley told SiliconRepublic.com. “I enjoy solving problems and helping improve the technology that supports people living with diabetes.”
If there is such a thing, can you describe a typical day on the job?
My day usually starts at 8am on-site in Abbott’s Diabetes Care division in Donegal, where I work in the Sensor Print Line department as a controls engineer. This is the first step in the process that produces sensors that are vital for diabetes care, so keeping the line running smoothly is critical. At 8:15am, we have a short but focused engineering and operations meeting where we align on priorities and assign tasks. It’s a great way to keep everyone on the same page and ensure critical actions are tackled first.
From there, no two days are the same. I might be troubleshooting equipment, programming PLCs, fine-tuning vision or motor control systems for IQA qualifications, or collaborating on process improvements. Managing workload is a balance of structured planning and reactive problem-solving. I keep a prioritised task list and stay flexible for unexpected issues. The ultimate goal? Keep the line running smoothly and safely while driving continuous improvement, because every sensor we produce plays a role in improving lives.
What types of projects do you work on?
I work on a variety of projects, from troubleshooting to optimising existing systems to commissioning new production lines. We’re also implementing new approaches to accommodate upcoming products, which adds an exciting layer of innovation. Working alongside experienced controls engineering colleagues and addressing day-to-day issues has developed my experience. These projects are critical because they help guarantee the required supply of devices that make a real difference to diabetes care worldwide.
What skills do you use on a daily basis?
Every day, I rely on a mix of technical and soft skills. On the technical side, PLC programming, motor control, and vision system configuration are core to my work. I also use diagnostic tools like JMP to monitor performance and troubleshoot issues quickly. Beyond that, problem-solving and adaptability are essential because production environments can change in an instant. My previous experience in multiple roles – as an operator, process lead, and validation engineer – has been invaluable. It gave me a deep understanding of manufacturing processes, quality standards, and team dynamics, which I draw on regularly.
What surprised me most was how much I’d need skills beyond engineering. Project management, stakeholder communication, and balancing priorities under pressure have become part of my day-to-day. I also didn’t expect to spend so much time analysing data, but this is a crucial skill for driving improvements and ensuring alignment across teams.
What are the hardest parts of your working day and how do you navigate them?
Debugging a PLC program or analysing data in JMP requires focus, but unexpected issues on the line can come up at any moment and need immediate attention. Switching between structured tasks and reactive problem-solving can be demanding. To manage this, I block time for critical work where possible. Another challenge is maintaining concentration during commissioning phases, which often involve long hours and tight deadlines. Clear communication with the team and setting realistic expectations helps keep things on track.
Do you have any productivity tips that help you through the day?
One of my biggest productivity tips is to document everything in OneNote. In controls engineering, there are multiple types of coding which means you may be tracking issues over several software platforms. Good documentation is essential as it provides clear information to colleagues who may need to work on the same issues later. For data analysis and troubleshooting, I rely on JMP to quickly identify trends and root causes, which speeds up decision-making. Another tip is to block time for deep work when possible, especially during programming or diagnostics, so I can maintain focus and deliver high quality results.
What skills and tools are you using to communicate daily with your colleagues?
Most of my communication happens through Microsoft Teams for quick updates, video calls and coordinating tasks. For formal updates, including communication with vendors, email is still widely used. Face-to-face communication on the production floor is also vital, you can solve problems faster and make sure you have strong alignment between engineering and operations teams. One of the most important communication skills in my role is explaining complex controls issues or software updates to colleagues who may not have a technical background. I focus on breaking down the information clearly and concisely without sounding condescending. This helps maintain trust and ensures everyone understands the impact of changes on production and quality.
How has this role changed as this sector has grown and evolved?
I’ve only been in this role for three years, so I haven’t seen all the long-term changes as I’m still gaining experience. However, it’s clear how quickly hardware and software versions change with advances in technology. Even in a short time, I’ve seen components and platforms needing updates to keep up with new standards and features.
What do you enjoy most about the job?
I love problem solving. There’s a real sense of satisfaction in diagnosing or resolving an issue, implementing a solution, and seeing the production line run smoothly again. I also enjoy the variety and complexity of the work. As a user of the FreeStyle Libre 2 Plus sensor we manufacture in Donegal, knowing that the systems I help to maintain contribute to producing devices that improve the lives of people with diabetes, makes my job even more meaningful.
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