Shapoorji Pallonji Group Interview Questions and Answers

Defects during product assembly can be of various types

• Missing parts or components

• Incorrectly installed parts

• Misaligned parts

• Loose or over-tightened fasteners

• Scratches or dents on the product

• Electrical or wiring issues

• Inconsistent product quality

• Incomplete assembly

• Poorly finished surfaces

Lean manufacturing is a systematic approach to minimize waste and maximize value in production processes.

• It focuses on continuous improvement and elimination of non-value adding activities.

• Tools include 5S, Kanban, Value Stream Mapping, and Just-in-Time production.

• It aims to increase efficiency, reduce lead times, and improve quality.

• Examples of lean manufacturing implementation include Toyota Production System and Lean Six Sigma.

The productivity of the assembly lines depends on various factors such as equipment, labor, and process efficiency.

• Productivity can be measured by the number of units produced per hour or day.

• Efficient use of equipment and labor can increase productivity.

• Process improvements such as reducing downtime and optimizing workflows can also boost productivity.

• Regular monitoring and analysis of productivity metrics can help identify areas for improvement.

• Benchmarking against industry...read more

TPM stands for Total Productive Maintenance. It is a maintenance strategy that aims to maximize equipment effectiveness and minimize downtime.

• TPM involves all employees in the maintenance process

• It focuses on proactive maintenance to prevent breakdowns

• There are 8 pillars of TPM, including autonomous maintenance, planned maintenance, and quality maintenance

• TPM aims to improve overall equipment effectiveness (OEE) by reducing downtime, improving quality, and increasing producti...read more

OEE stands for Overall Equipment Effectiveness. It is a measure of manufacturing productivity.

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

• Availability is the percentage of time the equipment is available for production.

• Performance is the percentage of the maximum speed the equipment is running.

• Quality is the percentage of good quality products produced.

• OEE = Availability x Performance x Quality

• A perfect OEE score is 100%.

• OEE can be used to identify...read more

I control non-conformity by implementing a quality management system and conducting regular audits.

• Implementing a quality management system to ensure all processes are standardized and documented

• Conducting regular audits to identify non-conformities and take corrective actions

• Training employees on quality standards and procedures to prevent non-conformities

• Establishing a system for reporting and investigating non-conformities

• Taking corrective actions to prevent recurrence of ...read more

Reducing manpower cost can be achieved through automation, process optimization, and outsourcing.

• Automate repetitive tasks to reduce the need for manual labor

• Optimize production processes to eliminate inefficiencies and reduce waste

• Consider outsourcing non-core functions to reduce the size of the workforce

• Implement training programs to improve employee skills and productivity

• Use technology to monitor and manage employee performance

• Offer incentives for employees who suggest co...read more

Managing union manpower requires effective communication, negotiation, and adherence to labor laws.

• Establish open communication channels with union representatives

• Negotiate fair and reasonable terms for wages, benefits, and working conditions

• Ensure compliance with labor laws and collective bargaining agreements

• Resolve disputes and grievances through mediation and arbitration

• Maintain positive relationships with union members to promote productivity and job satisfaction