OT Automation Engineer

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

Who We Are: Challenge Manufacturing’s mission is to manufacture with operational excellence by empowering our employee-owners. As a leading tier 1 supplier of complex metal assemblies for the global automotive industry, we drive innovative solutions for future mobility. We believe the best ideas come from individual unique perspectives. These ideas combined with the teamwork of industry leaders allow us to accomplish any challenge. Our team members take pride in the work we do and embody our core values of safety, ownership, and teamwork every day; they are the true driving force in our operations.

Challenge is proud to be one of the largest employee-owned automotive companies in North America. One of the many benefits of joining the Challenge team is the ESOP program. This program allows Challenge to give shares of the Company to all employee-owners annually. These shares are an additional retirement benefit that will continue to grow during your time at Challenge. Being part of an ESOP means our employee-owners share in Challenge’s success!

Challenge is#QualityDriven and #PeoplePowered!

Who We Want:

We are seeking an OT Automation Engineer to lead automation initiatives across multiple automotive plants. This role ensures high-performance, secure, and reliable OT/automation systems, including Rockwell PLCs, HMIs, and robotics systems are deployed and optimized to support high-volume production, Industry 4.0 initiatives, and new vehicle program launches.

The ideal candidate combines deep technical expertise in automation and robotics with multi-plant operational experience, driving efficiency, uptime, quality, and cross-functional collaboration.

What You Will Do:

• 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.
• 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.

Required Qualifications:

• Associates degree in Electrical, Mechanical, Mechatronics, or Robotics Engineering.
• 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.
• Strong problem-solving, analytical, and communication skills, with a track record of multi-site issue resolution.
• Multi-plant project management and new vehicle launch experience.
• Willingness to travel up to 25%.

Preferred Qualifications:

• Bachelor’s degree in Engineering, Technology Management, or Industrial Automation.
• 10+ years of multi-plant industrial automation and robotics experience.
• Robotics vendor certifications (Fanuc, ABB, Kawasaki).
• Experience with cobots, AMRs, AGVs, and AI/ML integration.
• Familiarity with Industry 4.0, digital twin, and predictive maintenance solutions.
• Automotive launch/change management experience in high-volume manufacturing.
• Leadership experience managing cross-functional OT and automation teams.