30+ Sun Vacuum Formers 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

A three-axis robot is a robotic system that operates in three dimensions, allowing it to move and manipulate objects in a wide range of directions.

• A three-axis robot typically consists of three linear axes, each capable of independent movement along a specific axis (X, Y, and Z).

• The X-axis controls horizontal movement, the Y-axis controls vertical movement, and the Z-axis controls depth or forward/backward movement.

• By combining movements along these three axes, the robot can ...read more

To control wastage and increase productivity, proper planning, training, and monitoring are necessary.

• Implement lean manufacturing techniques

• Train employees on efficient use of resources

• Monitor production processes to identify areas of improvement

• Implement quality control measures to reduce defects

• Optimize production schedules to reduce downtime

• Invest in automation to reduce manual labor

• Encourage employee feedback and suggestions for improvement

DC supply can be converted into AC supply using an inverter.

• Inverter is an electronic device that converts DC to AC.

• It uses a switching circuit to alternate the polarity of DC voltage.

• The output waveform can be modified using filters and transformers.

• Examples of inverters include square wave, modified sine wave, and pure sine wave inverters.

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

Calculating OEE, PPM, 7QC tool SPC, Injection Molding Defects, Tubrolsutting, and Red Bin Analysis in Production Engineering

• OEE can be calculated by multiplying Availability, Performance, and Quality

• PPM (Parts Per Million) is a measure of defects per million parts produced

• 7QC (Seven Quality Control) tools include Pareto charts, cause-and-effect diagrams, and control charts

• SPC (Statistical Process Control) involves monitoring and controlling a process to ensure it stays within...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.

Draw the electrical circuit to control barrel heater through SSR/contactor.

• Start by identifying the power source and the barrel heater.

• Connect the power source to the input terminals of the SSR/contactor.

• Connect the output terminals of the SSR/contactor to the barrel heater.

• Include appropriate fuses and circuit breakers for safety.

• Consider using a control signal (e.g., from a temperature controller) to trigger the SSR/contactor.

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

An injection molding machine is a manufacturing tool used to produce plastic parts by injecting molten material into a mold.

• It consists of a hopper, an injection unit, a clamping unit, and a control unit.

• The hopper is used to store the plastic material that will be melted and injected into the mold.

• The injection unit melts the plastic and injects it into the mold.

• The clamping unit holds the mold in place during the injection process.

• The control unit manages the entire process...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.

A product is a tangible or intangible item that is created through a process and offered for sale to satisfy a need or want.

• Products can be physical goods like electronics, clothing, or food

• Products can also be services like consulting, education, or healthcare

• Products can be digital goods like software, music, or e-books

HRTC, MTC, Chiller, Sequencer and Robot are all equipment used in production engineering.

• HRTC (High Rate Thermo Chiller) is used for cooling high power lasers in manufacturing.

• MTC (Multi-Temperature Chiller) is used for cooling multiple machines at different temperatures.

• Chiller is used for cooling various equipment in production.

• Sequencer is used to control the sequence of operations in a manufacturing process.

• Robot is used for automation in manufacturing processes.

There are various types of pumps used in engineering, including centrifugal pumps, reciprocating pumps, and rotary pumps.

• Centrifugal pumps are commonly used for transferring fluids by converting rotational energy into kinetic energy.

• Reciprocating pumps use a piston or plunger to create pressure and move fluid.

• Rotary pumps operate by trapping fluid between rotating components and the pump casing.

• Other types of pumps include diaphragm pumps, gear pumps, and peristaltic pumps.

The injection molding cycle involves several steps to produce a molded part.

• Clamping: The mold is closed and clamped tightly.

• Injection: Molten plastic is injected into the mold cavity.

• Cooling: The plastic solidifies and cools inside the mold.

• Ejection: The mold opens and the molded part is ejected.

• Cycling: The mold closes again for the next cycle.

Back pressure is the resistance or force exerted against the flow of a fluid or gas in a system.

• Back pressure occurs when there is a restriction or blockage in a system that hinders the flow of a fluid or gas.

• It can be caused by factors such as narrow pipes, clogged filters, or closed valves.

• Back pressure can lead to decreased efficiency, increased energy consumption, and potential damage to the system.

• In an engine, back pressure can affect the performance and efficiency of t...read more

LVDT stands for Linear Variable Differential Transformer, it is a type of sensor used to measure linear displacement.

• LVDT is a type of inductive sensor used to convert linear motion into an electrical signal.

• It consists of a primary coil and two secondary coils wound on a hollow tube, with a movable core inside.

• As the core moves, it induces a voltage in the secondary coils which is proportional to the displacement.

• LVDTs are commonly used in industrial applications for positio...read more

MSP stands for Maintenance Service Provider, which is a company or organization that provides maintenance services to clients.

• MSPs offer a range of maintenance services such as equipment repair, building maintenance, and facility management.

• They often have contracts with clients to provide ongoing maintenance support.

• MSPs may also offer preventative maintenance services to help clients avoid costly repairs in the future.

• Examples of MSPs include companies that provide HVAC mai...read more

Lubrication signal in injection molding machine indicates when the machine needs to be lubricated to ensure smooth operation.

• Lubrication signals can be visual indicators on the machine itself

• Some machines may have sensors that detect when lubrication is needed

• Regularly checking and following manufacturer's guidelines for lubrication is important

Injection molding is a manufacturing process used to produce parts by injecting molten material into a mold.

• Molten material is injected into a mold cavity

• The material cools and solidifies, taking the shape of the mold

• Commonly used for producing plastic parts

• Used in various industries such as automotive, medical, and consumer goods