Kohler Production Machine Operator Interview Questions and Answers

General questions related to Ceramic Engineering especially in the Whiteware domain

Q1. Work related technical questions
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Q2. Technical Functions and process related
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Q1. Describe your self
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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. What reason of pin hole in sanitary ware products.
Ans. 
Pin holes in sanitary ware products can be caused by various reasons.
• Presence of impurities in the raw materials used for manufacturing

• Inadequate mixing of raw materials

• Improper firing temperature or duration

• Poor glaze quality

• Inadequate cleaning of molds

• Inadequate drying time

• Inadequate pressure during casting

• Presence of air bubbles in the casting material

• Poor quality control measures

• Environmental factors such as humidi
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Q2. Howmany typs of crack
Ans. 
There are several types of cracks that can occur in materials.
• Fatigue cracks

• Corrosion cracks

• Thermal fatigue cracks

• Brittle cracks

• Overload cracks
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