OT Automation Engineer
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'll 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.
When and Where:
This will be a M-F position located at our Corporate Office in Walker, MI.
Occasionally, this may require you to arrive early, stay late, or work on weekends, outside of our regular hours, to ensure we successfully meet customer needs, deadlines, or urgent requests.
What You Need to Have:
- Associate degree in Electrical, Mechanical, Mechatronics, or Robotics Engineering required; Bachelor’s degree in Engineering, Technology Management, or Industrial Automation preferred.
- 5+ years of hands-on industrial automation experience in multi-plant automotive manufacturing required; 10+ years strongly preferred for senior-level candidates.
- Deep technical expertise with Rockwell PLCs, HMIs, and industrial robotics platforms such as Fanuc, ABB, and Kawasaki.
- Proven ability to standardize automation and controls practices across multiple sites.
- Experience integrating automation systems with MES, SCADA, IIoT, and data analytics platforms.
- Demonstrated success in leading or supporting multi-plant automation projects, including new vehicle program launches and plant expansions.
- Strong problem-solving, analytical, and communication skills, with a track record of resolving complex, multi-site technical issues.
- Experience with collaborative robots (cobots), autonomous mobile robots (AMRs), automated guided vehicles (AGVs), and AI/ML applications is highly desirable.
- Familiarity with Industry 4.0 technologies including digital twins, predictive maintenance, and advanced process analytics.
- Robotics vendor certifications (e.g., Fanuc, ABB, Kawasaki) a plus.
- Automotive launch/change management experience in high-volume production environments.
- Leadership or mentoring experience within cross-functional OT, automation, or controls engineering teams preferred.
- Understanding of OT cybersecurity best practices and secure network architectures for automation systems.
What We Offer:
We’re excited to offer a range of awesome benefits, including medical, dental, and vision insurance, a Health Savings Account with annual employer contributions, Flexible Spending Accounts, company-paid Short-Term Disability and Basic Life Insurance, Voluntary Life and Long-Term Disability options, an Employer 401k Match, ESOP shares, tuition reimbursement, a Referral Bonus Program, Challenge Incentive Program, and paid time off.
Please note, while these benefits are part of what we offer, they may not all apply to this specific role. The details shared in this job description are intended to give you a general idea, but duties and responsibilities may evolve over time, with or without notice. And of course, we’re happy to provide reasonable accommodations to help individuals with disabilities succeed in their role.
