Multi-Plant OT Automation Engineer – Industry 4.0 Lead

Challenge Manufacturing; Holland (MI); On-site; USD 90,000 - 130,000; Full time

Job summary

Challenge Manufacturing is seeking an OT Automation Engineer to lead multi-plant automation initiatives across our automotive facilities in Michigan. This role focuses on deploying and optimizing Rockwell PLCs, HMIs, and robotics, with Industry 4.0 initiatives and AI/ML for predictive maintenance.

You will collaborate with Production, Engineering, OT, IT teams to improve throughput, uptime, and quality KPIs, while establishing standardized practices, ensuring cybersecurity, and mentoring

Qualifications

• 5+ years of industrial automation experience in multi-plant automotive manufacturing.
• Hands-on experience with Rockwell PLCs, HMIs, and robotics systems (Fanuc, ABB, Kawasaki).
• Proven ability to standardize automation practices across multiple plants.
• Experience integrating automation systems with MES, SCADA, IIoT, and analytics platforms.

Responsibilities

• Lead design, deployment, and optimization of multi-plant automation systems, including Rockwell PLCs, HMIs, and robotics.
• Develop and standardize automation and controls practices across all plants to ensure consistency, reliability, and compliance with automotive standards (IATF 16949, ISO 10218).
• Oversee integration of automation systems with MES, SCADA, IIoT, and analytics platforms for real-time monitoring and predictive maintenance.
• Implement Industry 4.0 initiatives, including AI/ML for predictive maintenance, anomaly detection, and quality monitoring.
• Collaborate with Production, Engineering, OT, and IT teams to optimize throughput, line efficiency, uptime, and quality KPIs.
• Troubleshoot and resolve complex automation and robotics issues across multiple sites, ensuring rapid recovery and minimal production impact.
• Support new vehicle program launches and plant expansions with robust automation integration, testing, and commissioning.
• Establish automation KPIs, monitor performance across plants, and drive continuous improvement initiatives.
• Mentor and develop Controls & Robotics Engineers and technicians across sites.
• Ensure OT cybersecurity and secure connectivity for automation and robotics systems, in collaboration with IT/OT teams.

Skills

Automation leadership

Multi-plant experience

Problem solving

Travel up to 25%

Education

Associates degree in Electrical, Mechanical, Mechatronics, or Robotics Engineering

Tools

MES

SCADA

IIoT

Analytics platforms

Job description

Challenge Manufacturing is seeking an OT Automation Engineer to lead multi-plant automation initiatives across our automotive facilities in Michigan. This role focuses on deploying and optimizing Rockwell PLCs, HMIs, and robotics, with Industry 4.0 initiatives and AI/ML for predictive maintenance.

You will collaborate with Production, Engineering, OT, IT teams to improve throughput, uptime, and quality KPIs, while establishing standardized practices, ensuring cybersecurity, and mentoring