Bharat Forge Engineer Interview Questions, Process, and Tips

There are various types of welding processes used in engineering, such as MIG, TIG, stick, and flux-cored welding.

• MIG (Metal Inert Gas) welding uses a wire electrode and shielding gas to join metals together.

• TIG (Tungsten Inert Gas) welding uses a non-consumable tungsten electrode and shielding gas for precise and clean welds.

• Stick welding, also known as Shielded Metal Arc Welding (SMAW), uses a flux-coated electrode t...read more

Sheet metal manufacturing process involves cutting, bending, and assembling metal sheets to create various products.

• Cutting: Using tools like shears, lasers, or plasma cutters to cut the metal sheets into desired shapes.

• Bending: Utilizing press brakes to bend the metal sheets into specific angles and shapes.

• Assembling: Joining the cut and bent metal pieces together through welding, riveting, or fastening methods.

• Finish...read more

ECN stands for Engineering Change Notice and ECR stands for Engineering Change Request. They are used to document and implement changes in engineering designs.

• ECN (Engineering Change Notice) is a document used to communicate changes in engineering designs to relevant stakeholders.

• ECR (Engineering Change Request) is a formal proposal to make changes to an engineering design.

• ECRs are typically submitted by engineers or p...read more

Sheet metal techniques involve cutting, bending, and shaping metal sheets to create various components.

• Cutting techniques include shearing, sawing, and laser cutting.

• Bending techniques involve using a press brake or a roller to create bends in the metal.

• Shaping techniques can include stretching, shrinking, and deep drawing.

• Common sheet metal components include brackets, enclosures, and panels.

Simulation in Solidworks allows engineers to test designs virtually before physical prototyping.

• Solidworks Simulation helps analyze stress, vibration, thermal effects, and more on designs.

• It allows for optimization of designs to improve performance and reduce costs.

• Examples include testing the strength of a bridge design or analyzing heat dissipation in an electronic component.

• Simulation results can be used to make inf...read more

Tip stability procedure involves ensuring the stability of a structure or equipment's tip to prevent accidents or damage.

• Check the center of gravity of the structure or equipment

• Ensure proper anchoring or support for the tip

• Consider wind or external forces that may affect tip stability

• Regularly inspect and maintain the tip stability procedure

Fool proofing techniques are methods used to prevent mistakes or errors from occurring.

• Implementing thorough testing procedures

• Providing clear instructions and guidelines

• Using automation tools to reduce human error

• Implementing checks and balances in the system

• Training employees on best practices and potential pitfalls

There are three main types of defects in engineering: design defects, manufacturing defects, and usage defects.

• Design defects occur when there is an issue with the initial design of a product, leading to problems in its functionality or safety. For example, a car with a faulty braking system due to a design flaw.

• Manufacturing defects happen during the production process, resulting in a product that does not meet the in...read more

The 7 wastes refer to inefficiencies in a process that can be eliminated to improve productivity and quality.

• Transportation: Unnecessary movement of materials or products

• Inventory: Excess inventory leading to waste of resources

• Motion: Unnecessary movement of people

• Waiting: Idle time in a process

• Overproduction: Producing more than needed

• Overprocessing: Doing more work than necessary

• Defects: Errors that require rework or

Line balance refers to distributing workload evenly among different stations in a production line to optimize efficiency.

• Line balance ensures that each station in the production line has a similar amount of work to do.

• It helps in preventing bottlenecks and maximizing throughput.

• Line balance can be achieved by adjusting the cycle times at each station or by adding/subtracting workstations.

• An example of line balance is i...read more

To reduce defects and increase productivity, focus on continuous improvement, training, quality control, and efficient processes.

• Implement a quality control system to catch defects early on

• Provide regular training to employees to improve skills and knowledge

• Analyze data to identify root causes of defects and implement corrective actions

• Streamline processes to eliminate waste and improve efficiency

OEE stands for Overall Equipment Effectiveness, a measure of how well a manufacturing process is utilized.

• OEE is calculated by multiplying Availability, Performance, and Quality.

• Factors affecting OEE include equipment downtime, speed loss, and defects in production.

• Improving OEE involves reducing downtime, increasing production speed, and minimizing defects.

• For example, implementing preventive maintenance can reduce eq

CBM stands for Condition-Based Maintenance and TBM stands for Tunnel Boring Machine.

• CBM is a maintenance strategy that uses real-time data to determine the condition of equipment and schedule maintenance accordingly.

• TBM is a machine used to excavate tunnels with a circular cross-section through a variety of soil and rock strata.

• MTTR (Mean Time to Repair) is the average time required to repair a failed component or syst...read more

A hydraulic system is a technology that uses fluid to transmit power and control movement.

• Hydraulic systems use a fluid, typically oil or water, to transmit power.

• The system consists of a pump, valves, actuators, and fluid lines.

• The pump pressurizes the fluid, which is then distributed through the system.

• Valves control the flow and direction of the fluid.

• Actuators, such as cylinders or motors, convert the fluid pressur...read more

Implemented new quality control measures to reduce defects and improve product reliability.

• Introduced a new inspection process to catch defects earlier

• Trained employees on proper quality control techniques

• Updated equipment to improve accuracy and precision

• Collaborated with suppliers to ensure consistent quality of raw materials