10+ Sun Vacuum Formers Senior Engineer Interview Questions and Answers

Plan vs actual is comparing planned production output with actual production output. Production efficiency is calculated by dividing actual output by planned output.

• Plan vs actual is a comparison between the planned production output and the actual production output.

• Production efficiency is calculated by dividing the actual production output by the planned production output and multiplying by 100 to get a percentage.

• Formula: Production Efficiency = (Actual Output / Planned Ou...read more

SMED stands for Single-Minute Exchange of Die. It is required in molding machines to reduce setup time and increase efficiency.

• SMED is a lean manufacturing technique used to reduce setup time in manufacturing processes.

• It involves analyzing and streamlining the setup process to minimize downtime between production runs.

• By implementing SMED, companies can increase machine utilization and overall productivity.

• For molding machines, reducing setup time is crucial to meet producti...read more

MSA stands for Measurement System Analysis and SPC stands for Statistical Process Control. These tools are used in Quality to ensure accuracy and consistency in measurements and processes.

• MSA is used to assess the capability of a measurement system to provide accurate and reliable data.

• SPC is used to monitor and control processes to ensure they are stable and in control.

• MSA helps in identifying sources of variation in measurement systems, such as equipment, operators, and env...read more

Engineering materials are substances used to create products and structures, with specific properties like density and temperature requirements.

• Engineering materials are substances used in the design and construction of products and structures.

• Density refers to the mass per unit volume of a material.

• Temperature requirements indicate the range within which a material can perform effectively.

• Examples include steel (density: 7850 kg/m^3, temperature: -50°C to 1000°C) and aluminu...read more

PPM stands for parts per million, a measurement used to quantify the concentration of a substance in a solution. Rejection control involves identifying and addressing the root causes of rejected products to reduce ppm levels.

• PPM is a unit of measurement used to express very low concentrations of a substance in a solution.

• To control rejection, identify and address the root causes of rejected products such as quality issues, process inefficiencies, or material defects.

• Implement...read more

OEE stands for Overall Equipment Effectiveness. It is a measure of how well a manufacturing process is performing.

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

• Availability = (Operating Time / Planned Production Time) * 100%

• Performance = (Ideal Cycle Time * Total Count) / Operating Time * 100%

• Quality = Good Count / Total Count * 100%

• OEE = Availability * Performance * Quality

• For example, if a machine operates for 8 hours out of a planned 10 hours, wit...read more

To reduce part cycle time, optimize processes, improve equipment efficiency, and streamline workflows.

• Optimize processes to eliminate any unnecessary steps or delays

• Improve equipment efficiency by regular maintenance and upgrades

• Streamline workflows by implementing lean manufacturing principles

• Utilize automation and robotics to speed up production

• Train employees to work more efficiently and effectively

I have experience handling various types of moulding machines including injection moulding, blow moulding, and compression moulding machines.

• Injection moulding machines

• Blow moulding machines

• Compression moulding machines

Various types of materials have been used depending on the project requirements, including steel, concrete, wood, and composite materials.

• Steel is commonly used for structural components due to its strength and durability

• Concrete is often used for foundations and building structures

• Wood is used for interior finishes and decorative elements

• Composite materials are used in aerospace and automotive industries for their lightweight and high strength properties

PPAP, PDCA, PPE, APQP, DI, SOP, PPVT are all acronyms commonly used in engineering and manufacturing processes.

• PPAP - Production Part Approval Process: Ensures suppliers meet customer requirements for new or modified parts.

• PDCA - Plan-Do-Check-Act: Four-step management method used for continuous improvement.

• PPE - Personal Protective Equipment: Equipment worn to minimize exposure to hazards.

• APQP - Advanced Product Quality Planning: Framework used to develop products and proces...read more

Problem solving tools are techniques or methods used to identify, analyze, and solve complex issues or challenges.

• Root cause analysis

• Brainstorming

• SWOT analysis

• Fishbone diagram

• 5 Whys technique

Reduce flash by optimizing code, minimizing unnecessary animations, and using efficient image formats.

• Optimize code to reduce unnecessary animations and transitions

• Minimize the use of large image files and use efficient image formats like WebP or JPEG 2000

• Consider lazy loading images to reduce initial load time

• Use CSS sprites to combine multiple images into a single file to reduce HTTP requests

Core settings can be set by accessing the system's BIOS or UEFI interface.

• Access the system's BIOS or UEFI interface by pressing a specific key during startup (e.g. F2, Del, F10).

• Navigate to the 'Advanced' or 'Settings' menu to find options for setting core settings.

• Make changes carefully as incorrect settings can cause system instability or failure.

Case studies involve analyzing real-life situations to draw conclusions and make recommendations.

• Identify the key issues or problems in the case study

• Gather relevant information and data to analyze the situation

• Apply relevant theories or frameworks to analyze the case

• Draw conclusions and make recommendations based on the analysis

• Consider alternative solutions and their potential outcomes

Material grade refers to the quality or composition of a material, typically indicated by a specific code or designation.

• Material grade indicates the quality, composition, and properties of a material.

• It is often denoted by specific codes or designations, such as ASTM A36 for structural steel.

• Higher material grades generally indicate better quality or performance.

• Material grade is important in determining the suitability of a material for a specific application.

7 QC tools are a set of basic statistical tools used for quality control and process improvement.

• Check sheet: Used to collect and organize data in a structured format.

• Histogram: Represents data distribution visually to identify patterns.

• Pareto chart: Helps prioritize issues by showing the most significant factors.

• Cause-and-effect diagram (Fishbone diagram): Identifies root causes of a problem.

• Scatter diagram: Shows the relationship between two variables.

• Control chart: Monitor...read more

Quality is meeting or exceeding customer expectations consistently.

• Quality is about meeting customer requirements and expectations.

• It involves consistency in delivering products or services.

• Quality also includes continuous improvement and striving for excellence.

• Examples: Producing defect-free products, providing excellent customer service.