300+ Executive Production Interview Questions and Answers

Distillation is a process of separating components of a liquid mixture based on their different boiling points.

• Distillation involves heating a liquid mixture to vaporize the more volatile components.

• The vapor is then cooled and condensed back into a liquid, resulting in the separation of the components.

• The component with the lower boiling point will vaporize first and can be collected separately.

• Common examples of distillation include the production of alcoholic beverages and...read more

The principle of fat determination involves extracting fat from a sample and measuring its weight or volume.

• Fat is extracted using solvents or physical separation methods.

• The extracted fat is then weighed or measured to determine its quantity.

• Different methods may be used depending on the type of sample being analyzed.

• Common methods include Soxhlet extraction, acid hydrolysis, and gravimetric analysis.

• The principle is used in food production to ensure accurate labeling and qu...read more

The number of classes in a sterile area varies depending on the industry and regulations.

• The number of classes in a sterile area can range from 1 to 100+.

• In the pharmaceutical industry, there are typically four classes of sterile areas: Class A, Class B, Class C, and Class D.

• Each class has different requirements for air cleanliness and particle count.

• For example, Class A areas have the strictest requirements and are used for critical manufacturing processes.

• In healthcare faci...read more

To ensure smooth running of production and achieve monthly targets, we focus on efficient planning, effective communication, and continuous improvement.

• Develop a detailed production plan with clear timelines and milestones

• Regularly communicate with all stakeholders to ensure everyone is on the same page

• Identify and address any bottlenecks or issues that may arise during production

• Continuously monitor and analyze production data to identify areas for improvement

• Implement proce...read more

TPM stands for Total Productive Maintenance. My role in TPM activity is to ensure that all equipment and machinery are functioning at their optimal level to minimize downtime and increase productivity.

• TPM is a maintenance strategy that aims to maximize the efficiency and effectiveness of equipment and machinery

• It involves regular maintenance, cleaning, and inspection of equipment to prevent breakdowns and reduce downtime

• My role in TPM activity is to oversee the implementation...read more

Yes, I am familiar with spray dryer, drum dryer, and powder blending.

• Spray dryer is used to produce dry powders from a liquid or slurry by rapidly drying with hot gas

• Drum dryer is a type of rotary dryer used for drying liquid or slurry materials in a continuous process

• Powder blending involves mixing different powders or granules to create a homogeneous mixture

Equipment and area qualifications/validations ensure that all equipment and areas meet the required standards for production.

• Equipment and areas must be qualified and validated before use in production.

• Qualification ensures that equipment is installed and operates correctly.

• Validation ensures that equipment and areas consistently produce the desired results.

• Qualification and validation processes involve testing, documentation, and approval.

• Examples of equipment and areas that...read more

DG works as a backup power source during power failure.

• DG stands for Diesel Generator.

• It automatically starts when there is a power failure.

• It provides power to essential equipment and systems.

• It requires regular maintenance and fuel supply.

• Examples of essential systems powered by DG are elevators, emergency lights, and fire alarms.

I am requesting a 63% hike to align my salary with industry standards and reflect my increased responsibilities and contributions.

• My current salary is below market average for my role and experience level.

• I have taken on additional responsibilities and successfully delivered key projects.

• I have consistently exceeded performance targets and received positive feedback from colleagues and clients.

• A 63% increase would bring my salary in line with industry benchmarks and recognize...read more

Yes, I am ready for 15 days in the company and 15 days externally in another district.

• I am prepared to work for 15 days in the company and then spend the next 15 days in another district.

• I understand the requirement and am willing to adapt to the schedule.

• I have the necessary flexibility to handle the alternating work arrangement.

• I am open to new experiences and challenges that come with working in different locations.

Batch process involves processing a fixed quantity of material at a time, while continuous process involves a continuous flow of material.

• Batch process involves processing a fixed quantity of material at a time, while continuous process involves a continuous flow of material.

• Batch process is suitable for producing small quantities of products with different specifications, while continuous process is suitable for producing large quantities of standardized products.

• Batch proce...read more

GEMBA WALK, HACCP, kaizen, CCP, PRP, OEE, PRODUCTIVITY, OPL are all important concepts in executive production.

• GEMBA WALK involves managers going to the production floor to observe operations firsthand.

• HACCP (Hazard Analysis and Critical Control Points) is a systematic preventive approach to food safety.

• Kaizen is a Japanese business philosophy of continuous improvement.

• CCP (Critical Control Points) are specific points in the production process where control can be applied to ...read more

There are two main types of distillation: batch distillation and continuous distillation.

• Batch distillation involves separating a mixture into its components by heating it in a still and collecting the condensed vapors as they are produced.

• Continuous distillation involves feeding a mixture into a column and separating it into its components as it flows through the column.

• Other types of distillation include vacuum distillation, steam distillation, and fractional distillation.

• V...read more

AWC and CFC are abbreviations used in the Cadmach C300 compression machine.

• AWC stands for Automatic Weight Control, which is a feature that ensures consistent tablet weight during the compression process.

• CFC stands for Compression Force Control, which is a feature that monitors and adjusts the compression force applied during tablet formation.

• Both AWC and CFC contribute to the overall quality and uniformity of the tablets produced by the Cadmach C300 compression machine.

AHU is a part of HVAC system. AHU is a device that circulates air while HVAC is a system that controls temperature, humidity and air quality.

• AHU stands for Air Handling Unit

• AHU is a part of HVAC system

• AHU circulates air while HVAC controls temperature, humidity and air quality

• HVAC stands for Heating, Ventilation and Air Conditioning

• HVAC is a system that provides thermal comfort and acceptable indoor air quality

• Examples of HVAC systems include central heating, air conditioning...read more

The help of the resin packed in a column can be found using the formula: H = L / (1 - ε)

• Calculate the height of the resin packed in a column using the formula H = L / (1 - ε)

• H is the height of the resin packed in the column

• L is the length of the column

• ε is the void fraction of the resin bed

• The formula helps in determining the effective height of the resin bed in the column

Breakdown maintenance is done after preventive maintenance to address unexpected failures and ensure continuous operation of equipment.

• Preventive maintenance aims to reduce the likelihood of equipment failure through regular inspections and maintenance tasks.

• Despite preventive maintenance efforts, unexpected failures can still occur due to various factors such as wear and tear, environmental conditions, and operational stress.

• Breakdown maintenance is performed in response to ...read more

Inspection devices are tools used to examine and measure objects. Least count is the smallest measurement that can be read on the device.

• Inspection devices include calipers, micrometers, and gauges.

• They are used to ensure accuracy and quality in manufacturing and engineering.

• Least count is determined by the smallest division on the device's scale.

• For example, a micrometer with a least count of 0.01mm can measure to the nearest hundredth of a millimeter.

RMG stands for Resource Management Group. The principle of RMG is to efficiently manage and allocate resources to achieve organizational goals.

• RMG focuses on optimizing the use of resources such as time, money, and manpower.

• It involves identifying the needs of the organization and allocating resources accordingly.

• RMG also involves monitoring and evaluating the use of resources to ensure efficiency and effectiveness.

• For example, a company may use RMG to allocate funds for rese...read more

Reactors, types of reactors, distillation, pumps, and condensers are all important components in production processes.

• Reactors are vessels used to contain and control chemical reactions.

• Types of reactors include batch, continuous stirred-tank, and plug-flow reactors.

• Distillation is a process used to separate components of a mixture based on their boiling points.

• Pumps are used to move fluids through a system.

• Condensers are used to cool and condense vapors into liquids.

• Examples...read more

Planned deviation and change control are both related to managing changes in a project, but they differ in their nature and purpose.

• Planned deviation refers to a deliberate and pre-approved deviation from the original plan or specifications.

• Change control, on the other hand, is a systematic process for evaluating, approving, and implementing changes to the project.

• Planned deviation is typically used when there is a need to deviate from the plan due to unforeseen circumstances...read more

Increasing yield of paneer can be achieved through various methods.

• Using high-quality milk with high fat content

• Adding food-grade acid like lemon juice or vinegar to curdle the milk

• Using a cheesecloth to strain the curdled milk

• Pressing the paneer to remove excess water

• Using a paneer press to shape and compact the paneer

• Using additives like calcium lactate or citric acid to improve texture and yield

Effective communication, strategic planning, talent development, innovation

• Implementing clear communication channels to ensure all team members are aligned with organizational goals

• Developing and executing strategic plans to drive growth and achieve objectives

• Investing in talent development programs to nurture and retain top performers

• Fostering a culture of innovation to stay ahead of competitors and adapt to market changes

The critical process parameter during granulation is the moisture content of the granules.

• Moisture content affects the flowability and compressibility of the granules.

• It also impacts the final product quality and stability.

• Examples of critical moisture content ranges are 2-4% for wet granulation and 1-3% for dry granulation.

I will immediately stop the wet granulation process, secure the equipment, and address the power interruption before resuming production.

• Stop the wet granulation process immediately to prevent any damage to the equipment or product

• Secure the equipment to ensure safety and prevent accidents during the power interruption

• Address the power interruption by checking the power source, circuit breakers, and contacting maintenance if needed

• Resume production only after ensuring that th...read more

The Mediclaim limit of 50,000/Head may or may not increase depending on various factors.

• The increase in Mediclaim limit depends on the insurance provider's policies.

• Factors such as inflation, rising healthcare costs, and market trends can influence the decision to increase the limit.

• Insurance companies may periodically review and revise the Mediclaim limit based on the prevailing circumstances.

• The increase in Mediclaim limit can provide better coverage and financial protectio...read more

There are various types of distillation, such as fractional distillation, simple distillation, and vacuum distillation.

• Fractional distillation is used to separate mixtures with close boiling points, such as in the separation of different components of crude oil.

• Simple distillation is used to separate liquids with significantly different boiling points, such as in the purification of water.

• Vacuum distillation is used to distill substances at lower temperatures by reducing the ...read more

Key processes in pharmaceutical production include formulation development, manufacturing, quality control, and packaging.

• Formulation development involves designing the composition and dosage form of the drug.

• Manufacturing includes the actual production of the drug using various techniques such as blending, granulation, and compression.

• Quality control ensures that the final product meets regulatory standards for safety, efficacy, and purity.

• Packaging involves the proper packa...read more

Key Performance Indicators (KPI's) measured in the process include production efficiency, quality metrics, and cost effectiveness.

• Production efficiency - measuring the amount of output produced compared to the resources used

• Quality metrics - tracking the number of defects or errors in the production process

• Cost effectiveness - evaluating the expenses incurred in relation to the output generated

The question covers various topics related to transducers, sensors, encoders, thyristors, and LDRs.

• Whitestone bridge principle is used in strain gauge transducers to measure changes in resistance.

• Sensors convert physical quantities into electrical signals.

• Encoders are used to convert rotary motion into digital signals.

• Thyristors are semiconductor devices used for power control.

• LDRs are light-dependent resistors that change their resistance based on the amount of light they re...read more

Chlorine gas is heavier than air.

• Chlorine gas is approximately 2.5 times heavier than air.

• This means that chlorine gas will tend to sink and accumulate in low-lying areas.

• Inhaling chlorine gas can cause severe respiratory issues and even death.

Distillation is a process of separating components of a mixture based on their boiling points.

• There are two main types of distillation: batch distillation and continuous distillation.

• Batch distillation involves separating a mixture into its components in a single batch, while continuous distillation involves a continuous feed of the mixture.

• Other types of distillation include vacuum distillation, steam distillation, and fractional distillation.

• Vacuum distillation is used to s...read more

A fire extinguisher is a device used to control or extinguish small fires. There are different classes of fire extinguishers for different types of fires.

• Fire extinguishers are classified based on the type of fire they can extinguish.

• Class A fire extinguishers are used for fires involving ordinary combustibles like wood, paper, or cloth.

• Class B fire extinguishers are used for fires involving flammable liquids like gasoline or oil.

• Class C fire extinguishers are used for fires ...read more

Gun validation procedure is a process to ensure that a firearm is safe and functional.

• The gun is visually inspected for any damage or defects.

• The gun is disassembled and inspected for any wear or damage to internal parts.

• The gun is test fired to ensure that it functions properly.

• The gun's serial number is checked against a database to ensure that it is not stolen.

• The gun is marked with a unique identifier to indicate that it has been validated.

• The validation procedure may var...read more

Load cells are available in various parts of the machine.

• Load cells are commonly found in the weighing system of the machine.

• They can also be found in the material handling system to measure the weight of the material being moved.

• Load cells may be present in the machine's hydraulic or pneumatic systems to measure force or pressure.

• They can also be used in the machine's safety systems to detect overloading or excessive force.

• Load cells may be located in the machine's control p...read more

Types of heat exchangers include shell and tube, plate, and finned tube. Fillers used in the paper industry include kaolin, calcium carbonate, and talc. Types of compressors include reciprocating, rotary, and centrifugal.

• Types of heat exchangers: shell and tube, plate, finned tube

• Fillers used in paper industry: kaolin, calcium carbonate, talc

• Types of compressors: reciprocating, rotary, centrifugal

I handle multiple types of sifters depending on the production requirements.

• I handle rotary sifters for fine powders

• I handle vibratory sifters for larger particles

• I handle centrifugal sifters for high-capacity production

• I also handle specialized sifters for specific products such as magnetic sifters for removing metal contaminants

Implement quality control measures at every stage of production process to ensure product quality.

• Establish quality standards and procedures for each product

• Regularly inspect and test products during production

• Train production staff on quality control measures

• Implement corrective actions for any quality issues identified

• Utilize quality control tools such as Six Sigma or Total Quality Management

• Collaborate with suppliers to ensure quality of raw materials

• Conduct audits to moni...read more

An extruder is a machine used to create objects with a fixed cross-sectional profile. Extrusion works by pushing material through a die to create a specific shape.

• There are different types of extruders such as single screw, twin screw, and ram extruders.

• Extrusion involves heating the material above its glass transition temperature and then forcing it through a die to create the desired shape.

• Examples of extruded products include plastic pipes, rods, and sheets.

Filling machine can be qualified by performing various tests and inspections.

• Performing visual inspection of the machine

• Checking the accuracy of the filling volume

• Testing the machine's speed and efficiency

• Verifying the machine's compatibility with the product being filled

• Ensuring the machine meets regulatory requirements

• Conducting validation tests to ensure consistent performance

Deviation is the difference between actual and expected results. It can be positive or negative.

• Deviation is a measure of how far a result is from the expected value

• It can be calculated using the formula: deviation = actual value - expected value

• Positive deviation means the actual value is higher than expected, negative deviation means it's lower

• Types of deviation include absolute deviation, standard deviation, and relative deviation

The production target in Vice depends on various factors such as the type of product, production capacity, and demand.

• The production target can vary from day to day depending on the demand for the product.

• Factors such as production capacity and efficiency also play a crucial role in determining the production target.

• For example, if the production capacity is 1000 pcs per day and the demand is 800 pcs, the production target for the day would be 800 pcs.

• Regular monitoring and a...read more

End point in granulation refers to the point where the desired granule size is achieved.

• End point is determined by monitoring the granule size distribution.

• In RMG, the end point is usually achieved when the desired particle size is obtained and the moisture content is within the specified range.

• In FBD, the end point is reached when the desired particle size is achieved and the moisture content is within the specified range.

• The end point can also be determined by assessing the...read more

Centrifugal force is the apparent force that acts outward on a body moving around a center, arising from the body's inertia.

• Centrifugal force is not a real force, but rather a perceived force.

• It is the result of an object's inertia trying to keep it moving in a straight line while it is being forced to move in a circular path.

• Examples include the feeling of being pushed to the side in a car when turning a corner, or the water being pushed to the sides of a spinning bucket.

• Cen...read more

A pasteurizer is a machine used to heat liquids to a specific temperature to kill bacteria and extend shelf life.

• Used in food and beverage industry

• Commonly used for milk, juice, and beer

• Can be batch or continuous process

• Temperature and time are critical factors

• Helps to preserve nutrients and flavor

There are two types of charge control: constant current and constant voltage.

• Constant current charge control maintains a steady flow of current to the battery until it reaches a certain voltage level.

• Constant voltage charge control maintains a steady voltage level to the battery until the current drops to a certain level.

• Examples of charge control devices include battery chargers, solar charge controllers, and power banks.

The production process involves various activities and steps that are followed to manufacture a product.

• The process flow starts with the raw materials being received and inspected.

• The materials are then stored and transported to the production area.

• The production process involves various stages such as mixing, heating, cooling, and packaging.

• Quality checks are performed at each stage to ensure that the product meets the required standards.

• Once the product is ready, it is pack...read more