Grasim Industries Production Engineer Interview Questions and Answers

General questions related to Ceramic Engineering especially in the Whiteware domain

Q1. Describe your self
Ans. 
I am a dedicated and detail-oriented Production Engineer with a strong background in manufacturing processes and problem-solving.
• Experienced in optimizing production processes to improve efficiency and reduce costs

• Proficient in using CAD software to design and modify production equipment

• Skilled in troubleshooting and resolving technical issues on the production floor

• Strong knowledge of lean manufacturing principles and...read more
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Q2. Describe your job profile
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A Production Engineer is responsible for overseeing the manufacturing process and ensuring efficient production.
• Oversee the manufacturing process

• Ensure efficient production

• Identify and resolve production issues

• Implement process improvements

• Collaborate with cross-functional teams

• Monitor production metrics and analyze data

• Ensure compliance with safety and quality standards
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Q3. What is a lean manufacturing
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Lean manufacturing is a systematic approach to minimize waste and maximize value in production processes.
• Focuses on continuous improvement

• Eliminates non-value adding activities

• Involves all employees in the process

• Reduces lead time and inventory

• Examples: Toyota Production System, Kaizen, 5S
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Q4. What is use of 6 Sigma
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6 Sigma is a data-driven methodology used to improve quality and reduce defects in a process.
• It focuses on identifying and removing the causes of defects and minimizing variability in a process.

• It uses statistical analysis to measure and improve the performance of a process.

• It aims to achieve a level of quality where the probability of a defect occurring is less than 3.4 per million opportunities.

• It has been widely ado...read more
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Q5. What is your current company OEE
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Our current company OEE is 85%.
• OEE stands for Overall Equipment Efficiency.

• It is a measure of how effectively a manufacturing operation is utilized.

• It takes into account the availability, performance, and quality of the equipment.

• OEE is calculated by multiplying the availability, performance, and quality factors.

• A higher OEE indicates better productivity and efficiency.

• For example, if the availability is 90%, performan...read more
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Q6. What is a your line problem Solveig mathod
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Q7. Time study in assembly process
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Q8. Current company cost savings or kizen for improvement.
Ans. 
Implemented cost savings measures through process optimization and waste reduction.
• Conducted time and motion studies to identify areas for improvement

• Implemented lean manufacturing principles to reduce waste and increase efficiency

• Introduced new technologies to automate processes and reduce labor costs

• Negotiated better pricing with suppliers to reduce material costs

• Trained employees on cost-saving measures and encourag
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Q1. Work related technical questions
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Q2. Technical Functions and process related
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Q1. Manufacturing process
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Q2. What is raw material
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Raw material is the basic material used in the production of goods.
• Raw material is the primary substance or component used to manufacture products.

• It can be natural resources like wood, metal, or minerals.

• It can also be processed materials like chemicals or plastics.

• Raw materials are transformed into finished products through manufacturing processes.
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Q3. What is clinker
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Clinker is a nodular material produced during the cement manufacturing process.
• Clinker is a key ingredient in the production of cement.

• It is formed by heating limestone, clay, and other materials in a kiln.

• The cooled clinker is then ground into a fine powder to produce cement.

• The quality of clinker greatly affects the quality of the final cement product.
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Q4. What is packing plant kapisity
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Packing plant capacity refers to the maximum amount of products that can be processed and packaged in a plant within a specific time frame.
• Packing plant capacity is usually measured in units per hour or units per day.

• It is important for production engineers to optimize the packing plant capacity to meet demand and maximize efficiency.

• Factors that can affect packing plant capacity include equipment efficiency, productio
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Q5. What is coal mill kapisity
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Coal mill capacity refers to the maximum amount of coal that can be processed by the mill in a given time period.
• Coal mill capacity is typically measured in tons per hour or tons per day.

• It is important for production engineers to optimize coal mill capacity to meet production demands.

• Factors affecting coal mill capacity include the type of coal, moisture content, and mill design.

• Increasing coal mill capacity can invol...read more
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Q1. What is ball mill
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A ball mill is a type of grinder used to grind and blend materials for use in mineral dressing processes, paints, pyrotechnics, ceramics, and selective laser sintering.
• Consists of a hollow cylindrical shell rotating about its axis

• The axis of the shell may be horizontal or at a small angle to the horizontal

• The grinding media is the balls, which may be made of steel, stainless steel, ceramic, or rubber

• The inner surface o...read more
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Q2. What is raw mill
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Raw mill is a machine used in cement production to grind raw materials into a fine powder before being used in the kiln.
• Raw mill is used in the cement industry to grind raw materials like limestone, clay, and iron ore into a fine powder.

• The powdered raw materials are then blended and heated in a kiln to form clinker, which is the intermediate product in cement production.

• Common types of raw mills include ball mills, ro...read more
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Q1. Tell me about about yourself?family background.
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I come from a close-knit family with a strong work ethic and values.
• Family is very important to me and has played a significant role in shaping who I am today.

• My parents have always emphasized the importance of hard work and perseverance.

• I have a supportive family who has always encouraged me to pursue my goals and dreams.

• Growing up, I learned the value of teamwork and communication from my siblings.
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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,
Ans. 
HCl synthesis process, interlocks, and problems in HCl furnace.
• HCl synthesis involves combining hydrogen gas and chlorine gas in the presence of a catalyst.

• Interlocks in the process ensure safety measures are in place to prevent accidents.

• Common problems in HCl furnaces include corrosion, leaks, and temperature control issues.
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Q1. What will happen when flow of cooling water reduces in furnace?
Ans. 
Reduced flow of cooling water in furnace can lead to overheating, potential damage to equipment, and decreased efficiency.
• Overheating of furnace components

• Potential damage to furnace equipment

• Decreased efficiency in cooling process
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Q2. What is the impact when freon compressor got tripped and what to do ?
Ans. 
When a freon compressor gets tripped, it can lead to a loss of cooling capacity and potential damage to the system.
• Check for any fault codes or alarms on the compressor control panel.

• Inspect the compressor for any visible signs of damage or overheating.

• Reset the compressor and monitor its operation to ensure it is functioning properly.

• Investigate the root cause of the trip to prevent future occurrences.

• Consider contact...read more
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