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Painting and Coating Machine Operators

(A list of D.O.T.  codes is available on request.  See page 468.)

Nature of the Work

Paints and coatings are an important part of most products.  In
manufacturing, everything from cars to candy is covered by either
paint, plastic, varnish, chocolate, or some special coating
solution.  Often the paints and coatings are merely intended to
enhance the products' appeal to consumers, as with the chocolate
coating on candy.  More often, however, the protection provided by
the paint or coating is essential to the product, as with the
coating of insulating material covering wires and other electrical
and electronic components.  Many paints and coatings have dual
purposes, such as the paint finish on an automobile, which heightens
the visual appearance of the vehicle while providing protection from
corrosion.  Painting and coating machine operators control the
machinery and equipment that applies the many types of paints and
coatings to a wide range of manufactured products.

   Workers use several basic methods to apply paints and coatings to
manufactured articles.  For example, dippers immerse racks or
baskets of articles in vats of paint, liquid plastic, or other
solutions using a power hoist.  Tumbling barrel painters deposit
articles of porous materials in a barrel of paint, varnish, or other
coating, which is then rotated to insure thorough coverage.

   The most common method of applying paints and coatings is by
spraying the article with a solution.  Spray-machine operators use
spray guns to coat metal, wood, ceramic, fabric, paper, and even
food products with paint and other coating solutions.  Following a
formula, operators fill the equipment's tanks with a mixture of
paints or chemicals, adding prescribed amounts or proportions.  They
screw nozzles onto the spray guns and adjust them to obtain the
proper dispersion of the spray, and hold or position the guns to
direct the spray onto the article.  The pressure of the spray is
regulated by adjusting valves.  Operators check the flow and
viscosity of the paint or solution, and visually inspect the quality
of the coating.  They may also regulate the temperature and air
circulation in drying ovens.

   In response to concerns about air pollution and worker safety,
manufacturers are increasingly using new types of paints and
coatings on their products instead of high-solvent paints.
Water-based paints and powder coatings are two of the most common.
These compounds do not emit as many volatile organic compounds into
the air and can be applied to a wide variety of products.  Powder
coatings are sprayed much like liquid paints and heated to melt and
cure the coating.

   The switch to new types of paints is often accompanied by a switch
to newer, more automated painting equipment that the operator sets
and monitors instead of wielding a spray gun.  Operators position
the automatic spray guns, set the nozzles, and synchronize the
action of the guns with the speed of the conveyor carrying articles
through the machine and drying ovens.  The operator may also add
solvents or water to the paint vessel that prepares the paint for
application.  During operation, the operator attends the painting
machine, observes gauges on the control panel and randomly checks
articles for evidence of any variation of the coating from
specifications.  The operator then touches up spots where necessary
using a spray gun.

   Painting and coating machine operators use various types of spray
machines to coat a wide range of products.  Often their job title
reflects the specialized nature of the machine or coating they
apply.  For example, paper coating machine operators spray size on
rolls of paper to give it its gloss or finish.  Silvering
applicators spray silver, tin, and copper solutions on glass in the
manufacture of mirrors.  Enrobing machine operators coat, or enrobe,
confectionery, bakery, and other food products with melted
chocolate, cheese, oils, sugar, or other substances.

   Although the majority of painting and coating machine operators are
employed in manufacturing, the largest, best known group of them
work in automotive body repair and paint shops refinishing old and
damaged cars, trucks, and buses.  Automotive painters are among the
most highly skilled manual spray operators because, when painting
only the repaired portions of a vehicle, they often have to mix
paint to match the original color, which can be very difficult,
particularly if the color has faded.

   To prepare a vehicle for painting, automotive painters or their
helpers use power sanders and sandpaper to remove the original paint
or rust, and then fill small dents and scratches with body filler.
They also remove or mask parts they do not want painted, such as
chrome trim, headlights, windows, and mirrors.

   Automotive painters use a spray gun to apply several coats of paint.
They apply lacquer or enamel primers to vehicles with metal bodies
and flexible primers to newer vehicles with plastic body parts.
Aiming the spray gun by hand, they apply successive coats of paint
until the finish of the repaired sections of the vehicle matches
that of the original undamaged portions.  To speed drying between
coats, they may place the freshly painted vehicle under heat lamps
or in a special infrared oven.  After each coat of primer dries,
they sand the surface to remove any irregularities and to improve
the adhesion of the next coat.  Final sanding of the primers may be
done by hand with a fine grade of sandpaper.  A sealer is then
applied and allowed to dry, followed by the final topcoat.  When
lacquer is used, painters or their helpers usually polish the
finished surface after the final coat has dried; enamel dries to a
high gloss and usually is not polished.

   Respirators protect painters from toxic fumes.

Working Conditions

Painting and coating machine operators work indoors and may be
exposed to dangerous fumes from paint and coating solutions.
However, many operators wear masks or respirators that cover their
nose and mouth, and painting is usually done in special ventilated
booths that protect the operators from these hazards.  Provisions of
the Clean Air Act of 1990 regulate establishments' emissions of
volatile organic compounds, including those from paints and other
chemicals, thus decreasing the amount of hazardous fumes to which
these workers are exposed.

   Operators have to stand for long periods of time and, when using a
spray gun, they may have to bend, stoop, or crouch in uncomfortable
positions to reach all parts of the article.

   Most operators work a normal 40-hour week, but self-employed
automotive painters sometimes work more than 50 hours a week,
depending on the number of vehicles customers bring in to be
repainted.

Employment

Painting and coating machine operators held about 151,000 jobs in
1992.  Almost 9 of every 10 worked in manufacturing establishments
in the production of fabricated metal products, motor vehicles and
related equipment, industrial machines, household and office
furniture, and plastics, wood, and paper products, for example.
Others included automotive painters employed by independent
automotive repair shops and body repair and paint shops operated by
retail automotive dealers.  One of every 13 painting and coating
machine operators was self-employed; most of these were automotive
painters.

Training, Other Qualifications, and Advancement

Most painting and coating machine operators acquire their skills on
the job, usually by watching and helping experienced operators.  For
most operators, training lasts from a few days to several months.
However, becoming skilled in all aspects of automotive painting
usually requires 1 to 2 years of on-the-job training.

   Most automotive painters start as helpers and gain their skills
informally by working with experienced painters.  Beginning helpers
usually remove trim, clean and sand surfaces to be painted, mask
surfaces that they do not want painted, and polish finished work.
As helpers gain experience, they progress to more complicated tasks,
such as mixing paint to achieve a good match and using spray guns to
apply primer coats or final coats to small areas.

   Painters should have keen eyesight and a good color sense.
Completion of high school is generally not required but is
advantageous.  Additional instruction is offered at many community
colleges and vocational or technical schools.  Such programs enhance
one's employment prospects and can speed promotion to the next
level.

   Some employers sponsor training to make their workers more
productive by saving time on repainting and learning other efficient
methods.  This training is available from manufacturers of
chemicals, paints, or equipment or from other private sources.  It
may include safety and quality tips and knowledge of products,
equipment, and general business practices.

   Voluntary certification by ASE (the National Institute for
Automotive Service Excellence) is recognized as the standard of
achievement for automotive painters.  For certification, painters
must pass a written examination and have at least 2 years of
experience in the field.  High school, trade or vocational school,
or community or junior college training in automotive painting and
refinishing may substitute for up to 1 year of experience.  To
retain certification, painters must retake the examination at least
every 5 years.

   Experienced painting and coating machine operators with leadership
ability may advance to supervisory jobs.  Those who acquire
practical experience or college or other formal training may become
sales or technical representatives to large customers or for
chemical or paint companies.  Some automotive painters open their
own shops.

Job Outlook

Little change in employment of painting and coating machine
operators is expected through the year 2005 as technological
improvements enable these operators to work more productively.
Nevertheless, several thousand jobs will become available each year
as employers replace experienced operators who transfer to other
occupations or leave the labor force.  Turnover is moderately high,
reflecting the hazardous working conditions and wages that are below
other machine operative jobs.

   In manufacturing, employment of painting and coating machine
operators is expected to decline, reflecting the increasing
automation of paint and coating application.  Improvements in the
capabilities of industrial robots allow them to move and aim spray
guns more like humans.  Furthermore, as the cost of these machines
continues to fall, more should come into use, further expanding the
variety of manufactured articles that are painted or coated using
automatic equipment.

   The Clean Air Act of 1990, which sets limits on the level of
volatile organic compounds that can be released into the air, also
is reducing the demand for operators in manufacturing.  As firms
switch to water-based and powder coatings in order to comply with
the law, it is likely that many will upgrade their equipment in
order to increase the efficiency of the painting process.  In fact,
the powder coating process alone is much more efficient for work on
assembly lines than liquid sprays because no drying time is required
between coats and fewer operators are needed for touch-up painting.

   Employment of painting and coating machine operators in the auto
repair industry will grow more slowly than average.  The significant
cost of the new equipment required by the Clean Air Act could force
smaller or less profitable repair shops out of business and may
force the remaining shops to raise their prices.  This could
somewhat dampen demand.  Moreover, the improved quality of car
finishes and the increasing use of nonrusting alloys also may slow
the growth in demand for refinishing services.

   The number of job openings for painting and coating machine
operators may fluctuate from year to year due to cyclical changes in
economic conditions.  When demand for manufactured goods slackens,
production may be suspended or reduced, and workers may be laid off
or face a shortened workweek.  However, automotive painters can
expect relatively steady work because automobiles damaged in
accidents require repair and refinishing regardless of the state of
the economy.

Earnings

Painting and coating machine operators who usually worked full time
had median weekly earnings of $373 in 1992.  The middle 50 percent
had usual weekly earnings between $272 and $503, while the highest
10 percent earned more than $637 weekly.  Beginning automotive
painter apprentices usually start at about half the hourly rate of
fully qualified painters.  As they progress, their wages gradually
approach those of experienced automotive painters.  Helpers start at
lower wage rates than beginning apprentices.

   Many automotive painters employed by automobile dealers and
independent repair shops receive a commission based on the labor
cost charged to the customer.  Under this method, earnings depend
largely on the amount of work a painter does and how fast it is
completed.  Employers frequently guarantee commissioned painters a
minimum weekly salary.  Helpers and apprentices usually receive an
hourly rate until they become sufficiently skilled to work on a
commission basis.  Trucking companies, buslines, and other
organizations that repair their own vehicles usually pay by the
hour.

   Many painting and coating machine operators belong to unions,
including the International Association of Machinists and Aerospace
Workers; the International Union, United Automobile, Aerospace and
Agricultural Implement Workers of America; the Sheet Metal Workers'
International Association; and the International Brotherhood of
Teamsters; and the International Brotherhood of Painters and Allied
Trades.  Most union operators work for manufacturers and the larger
automobile dealers.

Related Occupations

Other occupations in which workers apply paints and coatings include
construction and maintenance painters, electrolytic metal platers,
and hand painting, coating, and decorating occupations.

Sources of Additional Information

   For more details about work opportunities, contact local
manufacturers, automotive-body repair shops, and automotive dealers;
locals of the unions previously mentioned; or the local office of
the State employment service.  The State employment service also may
be a source of information about training programs.

   For general information about a career as an automotive painter,
write to:

   Automotive Service Industry Association, 25 Northwest Point, Elk
Grove Village, IL 60007-1035.

   Automotive Service Association, Inc., P.O.  Box 929, Bedford, TX
76021-0929.

   Information on how to become a certified automotive painter is
available from:

   ASE, 13505 Dulles Technology Dr., Herndon, VA 22071-3415.


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