Sai Tools Project Engineer Interview Questions and Answers

The seven quality control tools are essential for process improvement and problem-solving in engineering.

• Check sheet: Used to collect and analyze data in a systematic way, such as tracking defects in a manufacturing process.

• Pareto chart: Helps identify the most significant factors contributing to a problem by displaying them in descending order of frequency or impact.

• Cause-and-effect diagram (Fishbone diagram): Visuali...read more

Autonomous maintenance is a key pillar of Total Productive Maintenance (TPM) and involves seven steps to empower operators to take care of their equipment.

• Step 1: Initial Cleaning - Operators clean the equipment and surrounding area to identify abnormalities.

• Step 2: Eliminate Sources of Contamination - Remove dirt, dust, and debris that can lead to breakdowns.

• Step 3: General Inspection - Operators visually inspect the ...read more

OEE calculations involve Availability, Performance, and Quality factors to measure equipment efficiency.

• Calculate Availability by dividing Operating Time by Planned Production Time.

• Calculate Performance by dividing Actual Production by Maximum Possible Production.

• Calculate Quality by dividing Good Units Produced by Total Units Started.

Implementing lean practices is mandatory for organizations to improve efficiency, reduce waste, and increase productivity.

• Lean practices help organizations identify and eliminate waste in processes, leading to cost savings and improved efficiency.

• By implementing lean practices, organizations can improve quality control and reduce defects in products or services.

• Lean practices promote continuous improvement and empower ...read more

Downstream team members can be motivated through recognition, clear communication, opportunities for growth, and fostering a positive work environment.

• Provide recognition for their hard work and achievements

• Communicate clearly about goals, expectations, and feedback

• Offer opportunities for growth and development, such as training or mentorship programs

• Create a positive work environment through team-building activities a

Pareto analysis is a technique used to identify the most important factors contributing to a problem or situation.

• Pareto analysis is based on the Pareto Principle, also known as the 80/20 rule, which states that roughly 80% of effects come from 20% of causes.

• It involves identifying and prioritizing the factors that have the most significant impact on a particular outcome.

• By focusing on addressing the most critical fact...read more

A Gemba walk is a Lean management technique where managers go to the actual workplace to observe operations and engage with employees.

• Gemba walks involve observing processes, asking questions, and identifying opportunities for improvement.

• Managers should focus on understanding the work being done and the challenges faced by employees.

• Gemba walks help in building relationships with employees and fostering a culture of c...read more

Steps involved in performing safety risk assessments

• Identify hazards and potential risks

• Assess the likelihood and severity of each risk

• Implement control measures to mitigate risks

• Monitor and review the effectiveness of control measures

• Document findings and recommendations

• Communicate risks to relevant stakeholders

TPM stands for Total Productive Maintenance, a proactive approach to maintenance that aims to maximize equipment effectiveness.

• TPM focuses on preventing equipment breakdowns through regular maintenance and employee involvement.

• It involves autonomous maintenance, planned maintenance, and focused improvement activities.

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