Belrise Industries Interview Questions and Answers

High pressure molding line is a manufacturing process where materials are compressed under high pressure to create products.

• Materials are placed in a mold cavity and compressed under high pressure to form the desired shape.

• Parameters such as temperature, pressure, and cooling time are carefully controlled to ensure quality and consistency.

• Examples of products made using high pressure molding line include automotive par...read more

Sand plant functions to wash, screen, and classify sand for various construction purposes.

• Sand plant washes the sand to remove impurities and clay particles.

• It screens the sand to separate different sizes for specific applications.

• Sand plant classifies the sand based on particle size and shape.

• Examples: Sand plants are used in concrete production, glass manufacturing, and foundries.

Sand plant additive dosing percentage is the amount of additive added to the sand in the plant to improve its properties. Controlling raw material consumption involves monitoring and adjusting the dosing percentage.

• Monitor the dosing percentage regularly to ensure it is within the desired range

• Adjust the dosing percentage based on the quality of the sand and production requirements

• Use automation and control systems to ...read more

DISA molding parameters and box size are crucial factors in controlling mold-related rejection.

• DISA molding parameters include factors like sand temperature, compactability, and moisture content.

• Box size refers to the dimensions of the mold box used in the molding process.

• To control mold-related rejection, ensure proper calibration of DISA molding parameters.

• Regularly monitor and adjust box size to meet the requirement...read more

Vertical pouring system involves pouring metal vertically into the mold, while horizontal pouring system involves pouring metal horizontally.

• Vertical pouring system allows for better control over the flow of metal into the mold.

• Horizontal pouring system is typically used for larger molds where the weight of the metal could cause issues in a vertical system.

• Challenges in vertical molding include ensuring even distributi...read more

Core making process involves creating sand cores to be placed inside molds for casting metal parts. Raw material control in core shop is crucial for quality cores.

• Core making process involves mixing sand with a binder to create a core that is then placed inside a mold for casting metal parts.

• Raw materials such as sand, binder, and additives need to be carefully controlled in terms of quality, quantity, and consistency ...read more

Shell core process is a method used in foundry casting to create hollow cavities in metal castings.

• Shell core process involves creating a shell of sand mixed with resin around a pattern to create a hollow cavity in the final casting.

• Parameters in shell core process include shell thickness, resin type, curing time, and shell permeability.

• Example: In automotive industry, shell core process is used to create complex engin...read more

IATF 16949 is a global standard for quality management systems in the automotive industry, focusing on continuous improvement.

• IATF 16949 emphasizes defect prevention and the reduction of variation and waste in the supply chain.

• It integrates with ISO 9001, ensuring a robust quality management system.

• The standard requires organizations to demonstrate their ability to provide products that meet customer and regulatory req...read more

Furnace capacity refers to the maximum amount of material that can be processed in a furnace at one time. In my previous organization, I handled high-grade steel in the furnace.

• Furnace capacity is crucial for determining production output and efficiency.

• Different types of furnaces have varying capacities based on their design and size.

• Handling high-grade materials in the furnace requires precise temperature control and...read more

Raw material consumption control in melting department involves monitoring and managing the usage of materials to ensure efficiency and cost-effectiveness.

• Regularly monitor raw material inventory levels

• Analyze consumption patterns and identify areas for improvement

• Implement measures to reduce waste and optimize material usage

• Collaborate with procurement team to ensure timely supply of materials

• Utilize software systems ...read more

The 7 QC tools are a set of basic statistical tools used for quality control and improvement in manufacturing and service industries.

• Check sheet: Used to collect and organize data in a systematic way.

• Histogram: Represents data distribution visually.

• Pareto chart: Helps identify the most significant factors contributing to a problem.

• Cause-and-effect diagram (Ishikawa or fishbone diagram): Identifies potential causes of a...read more

5S is a methodology used to organize a workplace for efficiency and effectiveness by identifying, sorting, setting in order, shining, and sustaining.

• Sort: Remove unnecessary items from the workplace

• Set in order: Organize remaining items in a logical manner

• Shine: Clean and inspect the workplace regularly

• Standardize: Establish procedures and schedules for maintaining the first 3 S's

• Sustain: Ensure the practices are consi...read more

4M is a method used in quality management to identify and address potential issues in a process.

• 4M stands for Man, Machine, Material, and Method.

• It is used to analyze and improve processes by considering the impact of these four factors.

• For example, in manufacturing, 4M can help identify if a quality issue is due to human error, machine malfunction, material defects, or the method of production.

TPM stands for Total Productive Maintenance, a proactive approach to maintenance involving all employees to improve equipment effectiveness.

• TPM focuses on maximizing equipment effectiveness through proactive maintenance

• The pillars of TPM include autonomous maintenance, planned maintenance, quality maintenance, focused improvement, early equipment management, and training & education

• Example: Implementing autonomous main...read more

JH stands for Job Hazard Analysis, a process used to identify and mitigate potential hazards in the workplace.

• JH is a systematic process for identifying potential hazards in a job task or process.

• It involves breaking down the job into steps, identifying potential hazards at each step, and implementing controls to mitigate those hazards.

• Examples of hazards that may be identified through JH include exposure to harmful ch...read more

I handle wagon malfunctions by identifying the issue, troubleshooting, and repairing the problem efficiently to minimize downtime.

• Conduct a thorough inspection to identify the root cause of the malfunction

• Utilize diagnostic tools and equipment to troubleshoot the issue

• Follow maintenance manuals and guidelines for proper repair procedures

• Prioritize safety protocols while working on the wagons

• Communicate effectively with...read more

To handle a paint shop conveyor breakdown, I would first assess the issue, troubleshoot the problem, repair or replace faulty parts, and ensure proper maintenance to prevent future breakdowns.

• Assess the issue by checking for any visible damage or obstructions on the conveyor

• Troubleshoot the problem by testing different components such as motors, belts, and sensors

• Repair or replace faulty parts as needed to restore the ...read more