40+ Interview Questions and Answers

Clearance, fit, allowances, and tolerance are important concepts in metrology.

• Clearance refers to the intentional gap between two mating parts.

• Fit refers to the degree of tightness or looseness between two mating parts.

• Allowances are the prescribed differences between the maximum and minimum limits of a dimension.

• Tolerance is the permissible limit of variation in a dimension.

• These concepts are crucial in ensuring the proper functioning of mechanical parts and assemblies.

A defect occurs when there is a deviation from the expected behavior or functionality of a product or system.

• Defects can occur at any stage of the development process, from design to implementation to testing.

• Defects can be caused by human error, faulty equipment, or environmental factors.

• Defects can manifest in various ways, such as crashes, errors, or incorrect output.

• Defects can be detected through various testing methods, such as unit testing, integration testing, and acc...read more

To reduce defects, identify the root cause and implement corrective actions.

• Conduct thorough analysis of the production process

• Identify the root cause of defects

• Implement corrective actions to address the root cause

• Train employees on proper procedures and quality control

• Regularly monitor and evaluate the effectiveness of the corrective actions

There are three main types of views shown in engineering drawings: front view, top view, and side view.

• Front view: Shows the object as it would appear from the front

• Top view: Shows the object as it would appear from the top

• Side view: Shows the object as it would appear from the side

Hardness can be measured using various methods depending on the material. Common methods include Brinell, Rockwell, and Vickers.

• Determine the appropriate method for the material being tested

• Prepare the surface of the material to be tested

• Apply a known force to the material using a specific indenter

• Measure the size of the indentation left on the material

• Calculate the hardness value using the appropriate formula

Balancing quantity and quality time in the working process is essential for efficiency and effectiveness.

• Prioritize tasks based on importance and deadlines to manage quantity and quality time effectively.

• Set realistic goals and deadlines to ensure quality work while also meeting quantity requirements.

• Regularly review and adjust your schedule to optimize productivity and maintain work-life balance.

• Use tools and techniques such as time blocking, Pomodoro technique, and task pri...read more

A motor is a device that converts electrical energy into mechanical energy. Types include AC motors (induction, synchronous) and DC motors (brushed, brushless).

• A motor is a device that converts electrical energy into mechanical energy

• Types of motors include AC motors (induction, synchronous) and DC motors (brushed, brushless)

• AC motors are commonly used in household appliances and industrial applications

• DC motors are often found in tools, toys, and automotive applications

Power factor is the ratio of real power to apparent power in an electrical system.

• Power factor is a unitless value between 0 and 1.

• It indicates how effectively electrical power is being converted into useful work output.

• A higher power factor signifies more efficient energy usage.

• Power factor can be improved by using power factor correction devices.

• Formula: Power Factor = Real Power / Apparent Power

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

• Focuses on continuous improvement

• Eliminates non-value adding activities

• Involves all employees in the process

• Reduces lead time and inventory

• Examples include Toyota Production System and Kaizen

Undersize and oversize refer to measurements that are smaller or larger than the standard size.

• Undersize refers to a measurement that is smaller than the standard size.

• Oversize refers to a measurement that is larger than the standard size.

• Undersize and oversize can apply to various objects, such as clothing, machinery parts, and tools.

• For example, an undersized bolt may not fit properly in a hole, while an oversized bolt may cause damage to the surrounding material.

Spur gears have straight teeth and are used for high speed applications, helical gears have angled teeth for smoother operation, and rack internal gears are used in linear motion systems.

• Spur gears have straight teeth that are parallel to the gear axis

• Helical gears have angled teeth for smoother and quieter operation compared to spur gears

• Rack internal gears are used in linear motion systems where a gear rotates around a fixed rack

Least count of vernier caliper is the smallest measurement that can be read accurately.

• It is the difference between the smallest division on the main scale and the smallest division on the vernier scale.

• For example, if the main scale has a smallest division of 0.1 cm and the vernier scale has a smallest division of 0.01 cm, then the least count is 0.01 cm - 0.1 cm = 0.09 cm.

• The least count varies depending on the precision of the instrument.

• It is important to consider the lea...read more

Helical gears have teeth at an angle, while spur gears have straight teeth. Speed is the rate of motion, viscosity is resistance to flow. Speed is measured in RPM, viscosity in cSt. Crankshaft rotation angle varies. Motors can be AC or DC.

• Helical gears have teeth at an angle, providing smoother and quieter operation compared to spur gears with straight teeth.

• Speed is the rate of motion of an object, while viscosity is the resistance of a fluid to flow.

• Speed is typically measu...read more

Delta series connection is a method of connecting three-phase AC circuits.

• In delta connection, each phase is connected to the adjacent phase forming a triangle or delta shape.

• It is commonly used in electric motors and transformers.

• The current rules for delta connection are that the line current is equal to the phase current and the phase voltage is equal to the line voltage divided by the square root of 3.

Vernier calipers come in two types: standard and digital.

• Standard vernier calipers have a main scale and a sliding vernier scale.

• Digital vernier calipers have a digital display for easy reading.

• Both types can measure internal and external dimensions, as well as depth and step measurements.

Daily electrical problems in our company include power outages, equipment malfunctions, and faulty wiring.

• Power outages due to grid failures or equipment overload

• Equipment malfunctions such as motor burnouts or circuit breaker trips

• Faulty wiring causing short circuits or electrical shocks

• Issues with electrical panels or transformers

• Problems with lighting systems or electrical outlets

The value of √3 is approximately 1.732.

• The square root of 3 is an irrational number.

• It is commonly approximated as 1.732.

• It is used in various mathematical calculations and engineering applications.

Seven quality tools are a set of techniques used for quality control and improvement.

• Check sheets

• Control charts

• Histograms

• Pareto charts

• Scatter diagrams

• Stratification

• Cause-and-effect diagrams

Technical documentation in Quality control includes procedures, work instructions, specifications, test methods, and records.

• Procedures outline the steps to be followed for quality control processes.

• Work instructions provide detailed instructions on how to perform specific tasks.

• Specifications define the requirements that a product or process must meet.

• Test methods describe the methods used to test product quality.

• Records document the results of quality control activities for...read more

There are several types of gears including spur gears, helical gears, bevel gears, worm gears, etc.

• Spur gears: Most common type with straight teeth

• Helical gears: Teeth are cut at an angle for smoother operation

• Bevel gears: Used to transmit motion between intersecting shafts

• Worm gears: Used for high reduction ratios and high torque applications

Gauges are instruments used to measure and display various parameters. There are different types of gauges for different applications.

• Analog gauges - display readings using a needle on a dial, such as a speedometer

• Digital gauges - display readings using numerical digits, such as a digital thermometer

• Pressure gauges - measure pressure of fluids or gases, such as a tire pressure gauge

• Temperature gauges - measure temperature, such as a thermometer

• Depth gauges - measure depth, su...read more

Manpower should be managed efficiently based on workload and skillset. Number of machines should be determined by production needs.

• Assess workload and determine required number of employees

• Ensure employees have necessary skills and training

• Implement performance metrics to track productivity

• Regularly review and adjust manpower and machine allocation based on production needs

• Consider automation and technology to optimize production

• Example: A manufacturing plant may require a ce...read more

Our company manufactures electrical equipment and components.

• We specialize in producing transformers, circuit breakers, and switchgear.

• Our products are used in a variety of industries, including power generation, transmission, and distribution.

• We also offer custom solutions for specific customer needs.

• Our manufacturing process is highly automated and utilizes advanced technology.

• We prioritize quality and safety in all aspects of our operations.

A transformer is a device that transfers electrical energy between two or more circuits through electromagnetic induction.

• Consists of two coils of wire, known as primary and secondary coils

• Primary coil receives electrical energy and creates a magnetic field

• Magnetic field induces a voltage in the secondary coil, transferring energy

• Used in power distribution, voltage regulation, and isolation

• Examples include step-up transformers for power transmission and step-down transformers...read more

Electrical maintenance involves the regular upkeep and repair of electrical systems to ensure they are functioning properly.

• Regular inspection of electrical systems

• Testing and troubleshooting electrical equipment

• Replacing faulty components

• Cleaning and lubricating machinery

• Updating software and firmware as needed

Types of transformers include step-up, step-down, isolation, autotransformer, and distribution transformers.

• Step-up transformer increases voltage output

• Step-down transformer decreases voltage output

• Isolation transformer provides electrical isolation between primary and secondary windings

• Autotransformer has a single winding with multiple taps for different voltage levels

• Distribution transformer is used to distribute electrical power in a local area

Basic components of the department include personnel, equipment, facilities, and processes.

• Personnel - employees, managers, supervisors

• Equipment - machinery, tools, technology

• Facilities - buildings, workspaces, storage areas

• Processes - procedures, workflows, protocols

Reading a drawing involves understanding the symbols, dimensions, and annotations used to represent a physical object.

• Identify the title block and read the drawing number, revision, and scale.

• Understand the symbols used to represent different features, such as circles for holes or lines for edges.

• Read the dimensions to understand the size and location of features.

• Pay attention to annotations, such as notes or callouts, for additional information.

• Use a ruler or other measuring...read more

Electrical safety refers to practices and measures taken to prevent electrical hazards and accidents.

• Ensuring proper grounding of electrical systems to prevent electric shocks

• Using insulated tools and equipment to prevent electrical contact

• Regular inspection and maintenance of electrical systems to identify and address potential hazards

• Following safety protocols and procedures when working with electricity

• Using personal protective equipment (PPE) such as gloves and goggles wh...read more

Electrical equipment refers to devices that are powered by electricity and used for various purposes.

• Electrical equipment includes items such as transformers, generators, motors, circuit breakers, and switches.

• These devices are essential for the generation, distribution, and utilization of electrical power.

• Electrical equipment can be found in various industries, homes, and commercial buildings.

• Regular maintenance and inspection of electrical equipment are crucial to ensure sa...read more

BMU machine is a medical device used for patient transfer and positioning.

• BMU stands for Bed Management Unit.

• It is used in hospitals for patient transfer and positioning.

• BMU machines have various features like height adjustment, tilting, and rotating.

• They are operated by trained medical professionals.

• BMU machines help in reducing the risk of injury during patient transfer.

A bearing is a machine element that allows one part to bear another part's weight and facilitate relative motion between the two parts.

• Bearing reduces friction between moving parts

• Common types include ball bearings, roller bearings, and plain bearings

• Used in various applications such as automotive, industrial machinery, and household appliances

IC engine stands for Internal Combustion Engine, which is a heat engine in which the combustion of fuel occurs inside the engine.

• IC engine converts chemical energy into mechanical energy through combustion of fuel within the engine

• Types of IC engines include petrol engines, diesel engines, and gas turbines

• Commonly used in vehicles, generators, and various machinery

• Examples: Car engines, motorcycle engines, power generators

Layout inspection is the process of verifying the visual appearance and positioning of elements on a webpage or application.

• It involves checking for consistency in design and alignment of elements

• It ensures that the layout is user-friendly and easy to navigate

• Examples include checking for proper spacing, font size, and color contrast

• Layout inspection is important for ensuring a positive user experience

Vernier calipers measure the least count of a measurement tool.

• Vernier calipers are used to measure the internal and external dimensions of an object with high precision.

• The least count of a Vernier caliper is the smallest measurement that can be read on the scale.

• It is typically 0.02 mm or 0.001 inches, depending on the scale of the caliper.

• The least count is determined by the number of divisions on the main scale and the Vernier scale.

Bearings are mechanical components that allow for smooth rotation or linear motion between two parts.

• Types of bearings include ball bearings, roller bearings, plain bearings, and fluid bearings.

• Ball bearings use balls to reduce friction between two surfaces.

• Roller bearings use cylindrical rollers to support radial and axial loads.

• Plain bearings have a sliding surface instead of balls or rollers.

• Fluid bearings use a thin layer of liquid or gas to support the moving parts.