Multi-Plant OT Automation Engineer (Rockwell, IIoT, AI/ML)

Challenge Manufacturing; Walker (MI); On-site; USD 95,000 - 125,000; Full time

Job summary

Challenge Manufacturing is seeking an OT Automation Engineer to lead multi-plant automation initiatives across our U.S. facilities. You will deploy Rockwell PLCs, HMIs, and robotics, advancing Industry 4.0, AI/ML for predictive maintenance, and real-time monitoring.

Ideal candidates have 5+ years in multi-plant automotive automation, strong problem-solving, and the ability to collaborate with OT, IT, Production, and Engineering teams. Travel up to 25% is required.

Qualifications

• Associates degree in Electrical, Mechanical, Mechatronics, or Robotics Engineering.
• 5+ years of multi-plant automotive automation experience.
• Hands-on with Rockwell PLCs, HMIs, and robotics systems (Fanuc, ABB, Kawasaki).
• Proven ability to standardize automation practices across multiple plants.
• Willingness to travel up to 25%.

Responsibilities

• Lead design, deployment, and optimization of multi-plant automation systems.
• 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.
• Evaluate, recommend, and deploy emerging automation technologies, including collaborative robots (cobots), AMRs, AGVs, and digital twin solutions.
• 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.
• Maintain detailed SOPs, technical documentation, system manuals, and disaster recovery plans for multi-plant operations.
• Participate in lean manufacturing initiatives and automation optimization projects.

Skills

Automation engineering

Cross-site collaboration

Problem solving

Communication

Travel willingness

Education

Assc. degree in Electrical/Mechanical/Mechatronics/Robotics

Bachelor’s degree preferred

Tools

Rockwell PLCs

Industrial robotics

MES/SCADA/IIoT

Job description

Challenge Manufacturing is seeking an OT Automation Engineer to lead multi-plant automation initiatives across our U.S. facilities. You will deploy Rockwell PLCs, HMIs, and robotics, advancing Industry 4.0, AI/ML for predictive maintenance, and real-time monitoring.

Ideal candidates have 5+ years in multi-plant automotive automation, strong problem-solving, and the ability to collaborate with OT, IT, Production, and Engineering teams. Travel up to 25% is required.