Challenge Manufacturing · 10 hours ago
Sr. OT Automation Engineer
Grand Rapids, MI
Full-time
Onsite
Senior Level
5+ years expChallenge Manufacturing is a leading tier 1 supplier of complex metal assemblies for the global automotive industry, focused on operational excellence through employee ownership. They are seeking a Senior OT Automation Engineer to lead automation initiatives across multiple plants, optimizing high-performance OT systems and driving Industry 4.0 transformation.
AutomotiveIndustrialManufacturing
Responsibilities
Provide technical and strategic leadership in the design, deployment, and optimization of automation systems across multiple plants, including Rockwell PLCs, HMIs, and robotics
Define, implement, and enforce standardized automation and controls practices to ensure consistency, system reliability, and adherence to automotive standards (IATF 16949, ISO 10218)
Lead integration efforts between automation systems and enterprise-level platforms including MES, SCADA, IIoT, and advanced analytics for real-time visibility and predictive insights
Drive Industry 4.0 initiatives such as AI/ML-based predictive maintenance, anomaly detection, and automated quality monitoring
Partner with Production, Engineering, OT, and IT stakeholders to deliver measurable improvements in throughput, line efficiency, system uptime, and product quality
Lead resolution of complex automation and robotics issues across sites, ensuring rapid root cause analysis, system recovery, and long-term corrective actions
Oversee automation readiness for new vehicle programs and plant expansions, ensuring seamless integration, testing, and commissioning
Evaluate and lead deployment of emerging automation technologies including collaborative robots (cobots), AMRs, AGVs, and digital twin platforms
Develop and manage plant-wide automation KPIs and drive continuous improvement initiatives across facilities
Provide mentorship and technical direction to Controls & Robotics Engineers and support staff across all sites
Collaborate with IT/OT teams to ensure automation systems follow OT cybersecurity best practices and secure network architecture
Maintain and oversee robust SOPs, system documentation, and disaster recovery strategies across the automation landscape
Champion lean manufacturing principles in automation design and continuous improvement projects
Qualification
Required
Associate or Bachelor's degree in Electrical, Mechanical, Mechatronics, Robotics Engineering, Industrial Automation, or related field
5+ years of hands-on industrial automation experience in multi-plant, high-volume automotive manufacturing (10+ years preferred for senior-level consideration)
Extensive experience with Rockwell PLCs, HMIs, and robotics systems (Fanuc, ABB, Kawasaki)
Proven ability to standardize automation practices and deploy scalable solutions across multiple sites
Experience integrating automation with MES, SCADA, IIoT, and analytics platforms
Strong troubleshooting, root cause analysis, and problem-solving skills in multi-site environments
Experience supporting new vehicle program launches and major plant expansion projects
Demonstrated leadership in mentoring or managing cross-functional OT and automation teams
Excellent communication, documentation, and cross-functional collaboration skills
Understanding of OT cybersecurity best practices and secure automation network design
Preferred
Robotics vendor certifications (Fanuc, ABB, Kawasaki) are a plus
Familiarity with collaborative robotics (cobots), AMRs, AGVs, and Industry 4.0 technologies, including digital twins and AI/ML-driven solutions
Automotive launch/change management experience in high-volume production environments
Benefits
Medical, dental, and vision insurance
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
Employer 401k Match
ESOP shares
Tuition reimbursement
Referral Bonus Program
Challenge Incentive Program
Paid time off
Company
Challenge Manufacturing
Challenge Manufacturing is an automotive company offering stamped and welded automotive assemblies.
1001-5000 employees
H1B Sponsorship
Challenge Manufacturing has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (9)
2024 (11)
2023 (11)
2022 (13)
2021 (6)
2020 (7)
Funding
Current Stage
Late StageTotal Funding
$100M2021-02-02Debt Financing· $100M
Leadership Team
Doug Bradley
President & CEO
Recent News
2025-08-05
Business Wire
2023-10-16
Company data provided by crunchbase