OT Automation Engineer

Challenge Manufacturing•Holland, MI

About The Position

Challenge Manufacturing is seeking an OT Automation Engineer to lead automation initiatives across multiple automotive plants. The role ensures high-performance, secure, and reliable operational technology and automation systems—including Rockwell PLCs, HMIs, and robotics—are deployed and optimized to support high-volume production, Industry 4.0 initiatives, and new vehicle program launches. The ideal candidate brings deep technical expertise in automation and robotics, multi-plant operational experience, and the ability to improve efficiency, uptime, quality, and cross-functional collaboration. Challenge Manufacturing is a leading tier 1 supplier of complex metal assemblies for the global automotive industry and is one of the largest employee-owned automotive companies in North America. Its employee-owners receive annual company shares through an ESOP program, providing an additional retirement benefit.

Requirements

Associate degree in Electrical, Mechanical, Mechatronics, or Robotics Engineering.
At least 5 years of industrial automation experience in multi-plant automotive manufacturing.
Hands-on experience with Rockwell PLCs, HMIs, and robotics systems, including Fanuc, ABB, or 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 resolving issues across multiple sites.
Multi-plant project management and new vehicle launch experience.
Willingness to travel up to 25%.

Nice To Haves

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

Responsibilities

Lead the design, deployment, and optimization of multi-plant automation systems, including Rockwell PLCs, HMIs, and robotics.
Develop and standardize automation and controls practices across plants to promote consistency, reliability, and compliance with automotive standards, including IATF 16949 and 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 applications 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, enabling rapid recovery and minimizing production impact.
Support new vehicle program launches and plant expansions through automation integration, testing, and commissioning.
Evaluate, recommend, and deploy emerging automation technologies, including 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 SOPs, technical documentation, system manuals, and disaster recovery plans for multi-plant operations.
Participate in lean manufacturing initiatives and automation optimization projects.