Esskay Group Head Production Manager Interview Questions and Answers

Q1. What is the process for installing a fan for plant operations?
Ans. 
The process for installing a fan for plant operations involves planning, preparation, installation, and testing.
• Plan the location of the fan for optimal air circulation

• Prepare the necessary tools and equipment for installation

• Install the fan according to manufacturer's instructions

• Test the fan to ensure proper functioning

• Ensure proper maintenance and regular checks for optimal performance
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Q2. What is the heat consumption required for manufacturing 1 metric ton of cement?
Ans. 
The heat consumption required for manufacturing 1 metric ton of cement varies depending on the type of cement and production process.
• Heat consumption can range from 3.6 - 6.0 GJ per metric ton of cement produced.

• Factors such as the type of kiln used, fuel type, and energy efficiency measures can impact heat consumption.

• For example, dry process cement production typically requires less heat compared to wet process produ
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Q1. What are your daily job responsibilities?
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Daily job responsibilities include overseeing production processes, managing staff, ensuring quality control, and meeting production targets.
• Overseeing production processes to ensure efficiency and quality

• Managing staff, including scheduling, training, and performance evaluations

• Ensuring quality control measures are in place and followed

• Meeting production targets and deadlines

• Collaborating with other departments to opt
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Q2. What is the process for balancing raw materials in production?
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Balancing raw materials in production involves accurately measuring and adjusting the quantities of each material to ensure optimal production output.
• Calculate the required quantities of each raw material based on the production schedule

• Monitor the inventory levels of each raw material to avoid shortages or excess

• Adjust the amounts of raw materials used in production based on quality control standards

• Utilize software s...read more
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Mathematics ,English and cement manufacturing process

Q1. HR sound Self introduction Qualification
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Q2. Technical Self introduction Technical questions Manufacturing process
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Q1. Which type of pc firing
Ans. 
PC firing refers to the type of firing system used in a power plant's boiler to ignite the fuel.
• PC firing stands for Pulverized Coal firing, where coal is ground into fine powder before being injected into the boiler combustion chamber

• It is a common method used in coal-fired power plants to efficiently burn coal and generate steam for electricity production

• Other types of firing systems include fluidized bed combustion
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Q2. Witch type of cooler house
Ans. 
The type of cooler house depends on the specific requirements of the production process, such as air flow, temperature control, and size.
• Cooling towers for large-scale industrial production

• Air conditioning units for smaller production facilities

• Evaporative coolers for energy-efficient cooling solutions

• Refrigeration units for temperature-sensitive production processes
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Q1. Witch stage of preheater
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The preheater stage in cement production is the calciner stage.
• The preheater typically consists of several stages including the cyclones and the calciner.

• The calciner stage is where the raw materials are heated to high temperatures before entering the rotary kiln.

• The calciner stage helps to reduce the energy consumption in the rotary kiln by preheating the raw materials.

• An example of a preheater configuration is a 4-st
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Q2. How much capacity
Ans. 
Capacity planning is crucial for ensuring optimal production output and resource utilization.
• Capacity planning involves assessing current production capacity and forecasting future needs.

• Factors to consider include equipment capabilities, workforce availability, and production demand.

• Examples of capacity planning tools include production scheduling software and simulation models.
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General methametics and basics of chemical engineering

Q1. Fluid dynamics heat transfer material balance
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Q2. Plant safety and quality control
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Q1. Personal details and general HR questions
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Q1. Basics about cement industry
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Q1. What is the benefits bonus or pf
Ans. 
Benefits, bonus, and PF (Provident Fund) are important components of an employee's compensation package.
• Benefits typically include health insurance, retirement plans, paid time off, and other perks provided by the employer.

• Bonuses are additional payments given to employees based on performance, company profits, or other criteria.

• Provident Fund (PF) is a mandatory retirement savings scheme in India, where both the emplo...read more
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Q2. What is the salary
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Q1. Tell me about about yourself?family background.
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Q2. Since I was from caustic chlorine background so they asked me about cl2 emergency handling ,TLV value
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Q3. Hcl synthesis process,and it's interlock ,problem in hcl furnace,
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Q1. What will happen when flow of cooling water reduces in furnace?
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Q2. What is the impact when freon compressor got tripped and what to do ?
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Q1. Work related technical questions
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Q2. Technical Functions and process related
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