3329) Paint Shop Jig Design Engineer – Plastic Parts

Role Purpose
To design, validate, and continuously improve paint shop jigs for plastic automotive parts by correctly identifying holding points, ensuring paintability, surface quality (Class-A / Piano Black), ergonomics, and high productivity in conveyorized and manual paint operations.

Key Responsibilities

1. Jig Design & Holding Point Identification (Core Skill)
2. Study plastic part geometry, Class-A surfaces, ribs, bosses, clips, snap features, and non-appearance areas.
3. Identify exact holding / clamping points that:

• Do not disturb Class-A or visible surfaces
• Avoid paint shadowing, thin film, edge build-up
• Prevent part distortion during hanging, curing, and cooling

1. Decide number of holding points based on:

• Part weight and CG
• Conveyor pitch and acceleration
• Oven temperature & sag risk

1. Finalize primary & secondary supports (hard stop, floating supports, spring-loaded pins where required).
2. Paint Process Compatibility
3. Design jigs compatible with:

• Primer, Basecoat, Clearcoat / 2-coat / 3-coat systems
• conventional spray guns

1. Ensure:

• Maximum paint exposure
• Minimal shadow areas
• Easy gun access at 45°–90° spray angles

1. Consider DFT uniformity, orange peel sensitivity, and gloss critical zones.
2. Jig Design & Detailing
3. Prepare:

• 2D manufacturing drawings
• 3D CAD models
• BOM for jig assemblies

1. Select appropriate:

• Jig materials (MS, SS, Aluminum)
• Insulation bushes / ceramic sleeves (for heat zones)

1. Design for:

• Quick loading/unloading
• Operator ergonomics
• Fool-proof part location (Poka-Yoke)

1. Trial, Validation & Shop Floor Support
2. Participate in:

• Paint trials
• First-off approval
• Jig buy-off

1. Analyze defects related to jig design:

• Paint skips
• Edge thinning
• Hook marks
• Sag due to wrong holding
• Implement on-line jig corrections quickly.

1. Continuous Improvement
2. Improve :

• Jig life
• Cycle time
• Part handling ease

1. Reduce:

• Rework
• Touch-ups
• Operator dependency
• Standardize best holding practices for similar parts.

Required Technical Skills (Must-Have)
Plastic Part Understanding

1. Injection molding features:

• Ribs, bosses, snap-fits
• Draft angles
• Sink-prone areas

1. Understanding of:

• Heat distortion temperature (HDT)
• Warpage behavior in oven

Jig & Fixture Knowledge

• Hanging jigs, pin jigs, clamp jigs
• Spring-loaded supports
• Floating locators
• Conveyor-mounted and trolley jigs

Paint Shop Knowledge (Preferred)

• Paint defect root causes related to jig design
• Masking vs jig holding trade-offs CAD & Tools
• AutoCAD / SolidWorks / NX / Creo (any one)
• Ability to read GD&T and plastic part drawings
• Jig trial checklists & validation sheets

Experience Requirement

• 5–10 years in automotive plastic paint shop jig design
• Preferred Hands-on exposure to:
• Conveyorized paint shops
• Direct involvement in part trials and shop floor problem-solving

Behavioral & Practical Skills

• Strong shop-floor mindset
• Ability to visualize paint flow and gun movement
• Fast decision-making during trials
• Good communication with:
• Production
• Quality
• Paint engineers

Key Performance Indicators (KPIs)

• First-time-right jig approval
• Reduction in paint defects due to jig
• Jig loading time
• Jig durability & maintenance frequency
• Line rejection reduction

Preferred (Added Advantage)

1. Experience in:

• Class-A / Piano Black parts
• Chrome-look or high-gloss finishes

1. Knowledge of:

• Oven airflow & temperature impact on jigs
• Static charge behavior in plastic parts