70+ Junior Engineer Production Interview Questions and Answers

Bearing is a device that supports and reduces friction between moving parts. Gear train is a system of gears that transmit power. Gear box is a device that houses gears and controls their speed. Octane number measures a fuel's resistance to knocking. Thermal conductivity is the ability of a material to conduct heat. Heat transfer rate is the amount of heat transferred per unit time.

• Bearing is used in machines to support rotating or moving parts.

• Types of bearings include ball ...read more

Interview questions for Junior Engineer Production related to transformers, circuit breakers, and loads.

• Transformer is an electrical device that transfers electrical energy from one circuit to another through electromagnetic induction.

• The function of a transformer is to step up or step down the voltage level of an alternating current (AC) power supply.

• Types of transformers include power transformers, distribution transformers, autotransformers, isolation transformers, and ins...read more

Poka yoke is a Japanese term for mistake-proofing, a technique used to prevent errors or defects in a process.

• Poka yoke aims to eliminate human errors by designing processes or systems that prevent mistakes from occurring.

• It involves implementing mechanisms or devices that detect and prevent errors at the source.

• Examples of poka yoke include using sensors to detect missing components in assembly lines or designing products with foolproof features.

• Poka yoke helps improve quali...read more

Interview questions for Junior Engineer Production related to spot welding, troubleshooting, OEE, types of welding and body shop department.

• Spot welding is a process of joining two metal surfaces by applying heat and pressure at specific points.

• To troubleshoot breakdowns, identify the root cause, check for loose connections, and perform regular maintenance.

• OEE stands for Overall Equipment Effectiveness and is calculated by multiplying availability, performance, and quality.

• Ty...read more

No, petrol cannot be used in a diesel engine and vice versa due to differences in fuel properties and engine design.

• Petrol and diesel have different chemical compositions and ignition properties.

• Petrol engines use spark plugs to ignite the fuel-air mixture, while diesel engines rely on compression ignition.

• Using the wrong fuel can damage the engine and lead to poor performance or even engine failure.

• For example, using petrol in a diesel engine can cause incomplete combustion,...read more

The candidate has experience in manual soldering and line leading. They have led 2 projects and have a hobby of singing.

• Experienced in manual soldering

• Has led 2 projects as a line leader

• Hobby of singing

To fix a mistake, I analyze the root cause, take responsibility, communicate with stakeholders, and implement a solution.

• Analyze the root cause of the mistake to understand what went wrong

• Take responsibility for the mistake and acknowledge it to relevant parties

• Communicate with stakeholders to keep them informed about the situation

• Implement a solution to rectify the mistake and prevent it from happening again

• Example: In a previous role, I made an error in a production report....read more

Press shop is a manufacturing facility where metal sheets are cut, shaped, and formed into various components using presses.

• Press shop is an integral part of the metalworking industry.

• It involves the use of presses to cut, shape, and form metal sheets into various components.

• The components produced in a press shop are used in various industries such as automotive, aerospace, and construction.

• The press shop may also involve the use of other equipment such as shears, punches, a...read more

Value stream mapping is a lean manufacturing technique used to analyze and improve the flow of materials and information required to bring a product or service to a customer.

• It involves creating a visual representation of the entire process from start to finish

• Identifying areas of waste and inefficiency

• Developing a plan to eliminate waste and improve efficiency

• It helps to reduce lead time, improve quality, and increase customer satisfaction

• Example: A value stream map for a ca...read more

Answering interview questions for Junior Engineer Production

• 1. To manage high absenteeism, we can implement a system of rewards and recognition for employees with good attendance records.

• 2. If rejection is coming while the line is running, we need to identify the root cause of the rejection and take corrective action immediately.

• 3. I am not aware of the last customer complaint of the company.

Cycle time is the time required to complete a process or operation.

• Cycle time is an important metric in production and manufacturing.

• It helps in identifying bottlenecks and improving efficiency.

• It can be measured using various tools such as stopwatches, sensors, and software.

• Quality is also an important aspect of production and can be measured using various techniques such as statistical process control.

• Jh and boiler are specific equipment used in certain industries such as p...read more

Line balancing is the process of optimizing workloads across a production line to improve efficiency.

• It involves analyzing the tasks required to complete a product and distributing them evenly among workers and machines.

• The goal is to eliminate bottlenecks and reduce idle time, ultimately increasing productivity.

• Line balancing is commonly used in manufacturing and assembly line settings.

• Example: A car manufacturer may use line balancing to ensure that each worker on the assem...read more

Turbines are used to convert fluid energy into mechanical energy. There are various types of turbines.

• Types of turbines include steam turbines, gas turbines, and hydraulic turbines.

• Steam turbines are used in power plants to generate electricity by using steam to rotate the turbine blades.

• Gas turbines are commonly used in aircraft propulsion and power generation.

• Hydraulic turbines are used in hydroelectric power plants to convert the energy of flowing water into mechanical ene...read more

Refrigeration plants are used for cooling large spaces or products, while AC plants are used for cooling smaller spaces like homes or offices.

• Refrigeration plants are used in industrial settings to cool large spaces or products, such as in food processing or storage facilities.

• AC plants are used in residential or commercial settings to cool smaller spaces like homes, offices, or retail stores.

• Refrigeration plants typically operate at lower temperatures and are designed for co...read more

MIG and spot welding are common welding techniques used in production. Welding defects can occur and need to be remedied.

• MIG welding, also known as Gas Metal Arc Welding (GMAW), uses a consumable wire electrode and shielding gas to join metal pieces together.

• Spot welding is a resistance welding process that uses two copper alloy electrodes to apply pressure and heat to join metal sheets.

• Common welding defects include porosity, undercutting, lack of fusion, and distortion.

• Reme...read more

Steel is an alloy of iron and carbon, known for its strength, durability, and versatility.

• Steel is primarily composed of iron and carbon, with small amounts of other elements.

• It is produced by heating iron ore in a blast furnace and adding carbon to reduce the iron oxide.

• The carbon content in steel determines its strength and hardness.

• Steel is widely used in construction, manufacturing, transportation, and various other industries.

• Examples of steel products include buildings,...read more

GD&T stands for Geometric Dimensioning and Tolerancing. It is a system for defining and communicating engineering tolerances.

• GD&T is used to specify the allowable variations in form, size, and orientation of features on a part.

• Some common GD&T symbols include concentricity, perpendicularity, flatness, and position.

• Geometric characters in GD&T include circles, squares, triangles, and various other shapes.

• Types of tolerance in GD&T include position, profile, concentricity, and ...read more

CCS is the ability of a material to withstand compressive load at room temperature. Porosity refers to the presence of voids in a material. Kiln inclination is the angle at which the kiln is tilted.

• CCS is an important property for materials used in construction and refractory applications.

• Porosity affects the strength and durability of a material.

• Kiln inclination is a critical factor in the production of cement and other materials.

• CCS is measured in units of pressure, typical...read more

Lean manufacturing focuses on minimizing waste and maximizing efficiency. UPH and UPPH are productivity metrics. 7 QC tools are used for quality control. Why-Why analysis is a problem-solving technique. CAPA stands for Corrective and Preventive Actions. ESD refers to Electrostatic Discharge. OEE is Overall Equipment Effectiveness.

• Lean manufacturing aims to eliminate waste and improve efficiency in production processes.

• UPH (Units Per Hour) and UPPH (Units Produced Per Hour) ar...read more

CPM and PERT are project management techniques used to plan and schedule tasks.

• CPM stands for Critical Path Method and PERT stands for Program Evaluation and Review Technique.

• CPM is used for projects with known activity times, while PERT is used for projects with uncertain activity times.

• CPM uses a single time estimate for each activity, while PERT uses three time estimates (optimistic, pessimistic, and most likely) to calculate expected activity times.

• CPM focuses on identify...read more

I have a fluent handle in Statistical Process Control (SPC) in manufacturing.

• Knowledge of control charts such as X-bar and R charts, p-charts, and c-charts

• Ability to analyze process data to identify trends, variations, and out-of-control conditions

• Experience in implementing corrective actions based on SPC analysis results

• Understanding of process capability and control limits

• Proficiency in using SPC software tools like Minitab or JMP

Tig welding, rolling, milling, shaper and planer are all different manufacturing processes used in metalworking.

• Tig welding is a type of arc welding that uses a tungsten electrode to produce the weld.

• Rolling is a process of reducing the thickness of a metal sheet or plate by passing it through a set of rollers.

• Milling is a process of cutting and shaping metal using a rotating cutting tool.

• Shaper is a machine tool used for shaping metal or other materials by removing material ...read more

Refrigeration systems work on the principle of removing heat from a space to lower its temperature.

• Refrigeration systems use a refrigerant to absorb and release heat through a cycle of compression and expansion.

• The refrigerant absorbs heat from the space to be cooled, then releases it outside the space.

• The cycle continues to maintain a lower temperature inside the space.

• Examples of refrigeration systems include air conditioners, refrigerators, and freezers.

An engraving machine is a device used to etch or carve designs onto various materials.

• Engraving machines use various techniques such as laser, rotary, or diamond-tipped tools to create precise and detailed designs.

• They are commonly used in industries like jewelry making, woodworking, and metalworking.

• Engraving machines can work on materials like metal, wood, glass, plastic, and even stone.

• The machine operates by following a pre-programmed design or by manually controlling the...read more

A cooler is a device used to lower the temperature of a substance, while a condenser is a device used to convert a gas or vapor into a liquid state.

• Cooler is used to cool down a substance, while a condenser is used to convert a gas or vapor into a liquid state.

• Cooler typically operates at a higher temperature range compared to a condenser.

• Cooler is commonly used in refrigeration systems, air conditioning units, and heat exchangers, while condensers are used in distillation pr...read more

The SOP of this Company outlines the standard operating procedures and guidelines for production processes.

• The SOP includes detailed instructions on how to perform specific tasks in the production department.

• It outlines safety protocols to ensure a safe working environment for employees.

• The SOP also covers quality control measures to maintain product standards.

• Regular updates and revisions are made to the SOP to reflect changes in technology or regulations.

MSDS stands for Material Safety Data Sheet. It contains details about the hazards, handling, storage, and emergency procedures for a specific chemical or product.

• MSDS provides information about the physical and chemical properties of a substance.

• It includes details about the potential hazards associated with the substance and the necessary precautions to be taken.

• MSDS also provides information on proper storage, handling, and disposal methods.

• Emergency procedures and first ai...read more

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

• Distillation involves heating a liquid mixture to create vapor, then cooling the vapor to collect the separated components.

• Types of distillation include simple distillation, fractional distillation, and steam distillation.

• Simple distillation is used for separating components with significantly different boiling points, while fractional distillation is used for components wi...read more

To reduce rejection in powder coating, proper surface preparation, correct powder application, and regular equipment maintenance are essential.

• Ensure proper surface preparation by cleaning and degreasing the substrate before coating.

• Use the correct powder application techniques such as proper gun settings and consistent film thickness.

• Regularly maintain and calibrate equipment to ensure uniform coating and prevent defects.

• Implement quality control measures such as visual insp...read more

Yes, I am familiar with measuring readings on Vernier.

• Vernier is a measuring tool used to measure small distances with high accuracy.

• It consists of a main scale and a sliding vernier scale.

• To take a reading, align the zero mark on the vernier scale with the closest mark on the main scale.

• Then, read the value on the vernier scale that lines up with a mark on the main scale.

• The final reading is the sum of the main scale reading and the vernier scale reading.

• For example, if the ...read more

Casting and welding defects are common in production. Casting defects include porosity, shrinkage, and misruns. Welding defects include cracks, porosity, and incomplete fusion.

• Casting defects can be caused by improper mold design, incorrect pouring temperature, or inadequate cooling time.

• Porosity is a common casting defect caused by trapped gas in the molten metal.

• Shrinkage occurs when the metal cools and contracts, causing voids in the casting.

• Misruns happen when the metal d...read more

Unit operations for mass transfer involve processes like distillation, absorption, extraction, and adsorption.

• Distillation: Separation of components based on boiling points.

• Absorption: Transfer of a solute from gas phase to liquid phase.

• Extraction: Transfer of a solute from one liquid phase to another.

• Adsorption: Adhesion of molecules to a surface.

The combination of red and blue is purple.

• Red and blue are primary colors.

• When red and blue are mixed together, they create the secondary color purple.

• The intensity of red and blue can affect the shade of purple obtained.

I expect a salary of 3LPA from VVDN.

• Based on my research and experience, I believe a salary of 3LPA is reasonable for a Junior Engineer Production position at VVDN.

• I am open to negotiation and would be willing to discuss the salary further.

• I am more interested in the growth opportunities and learning experiences that VVDN can offer me.

• I have researched the industry standards and believe that 3LPA is a fair compensation for my skills and qualifications.

Production is the process of creating goods or services, while manufacturing is the process of making physical products.

• Production involves both goods and services, while manufacturing is limited to physical products.

• Production is a broader term that includes manufacturing as a subset.

• Manufacturing involves the use of machinery and tools to create physical products.

• Production can be done manually or with the help of machines.

• Examples of production include software development...read more

SPM machine stands for Special Purpose Machine. It is a machine designed to perform specific tasks with high precision and efficiency.

• SPM machines are custom-built machines that are tailored to perform a specific operation or set of operations.

• They are used in various industries such as automotive, aerospace, electronics, and manufacturing.

• SPM machines are designed to optimize production processes, increase productivity, and reduce human error.

• They can be automated or semi-au...read more

2 stroke engines have simpler design and produce more power, but are less fuel efficient and emit more pollution than 4 stroke engines.

• 2 stroke engines complete a power cycle in one revolution of the crankshaft, while 4 stroke engines complete it in two revolutions

• 2 stroke engines have fewer moving parts and are lighter than 4 stroke engines

• 2 stroke engines produce more power per unit of displacement than 4 stroke engines, but are less fuel efficient

• 2 stroke engines emit more...read more

Types of pumps, types of heat exchangers, and hydrostatic pressure calculation.

• Types of pumps: centrifugal pumps, reciprocating pumps, rotary pumps, etc.

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

• Hydrostatic pressure calculation: P = ρgh, where P is the pressure, ρ is the density of the fluid, g is the acceleration due to gravity, and h is the height of the fluid column.

A boiler is a closed vessel in which water or other fluid is heated to generate steam or hot water.

• Boilers are commonly used in industries for various purposes such as power generation, heating, and processing.

• They work by transferring heat from a fuel source to the water or fluid inside the boiler.

• The heated water or fluid then circulates through pipes or tubes to provide heat or generate steam.

• Boilers can be classified into different types based on their design, fuel type, ...read more

A pump is a mechanical device used to move fluids from one place to another. There are different types of pumps based on their working principle and application.

• Pumps can be classified into two main types: positive displacement pumps and centrifugal pumps.

• Positive displacement pumps move fluid by trapping a fixed amount and forcing it into a discharge pipe. Examples include piston pumps and diaphragm pumps.

• Centrifugal pumps use a rotating impeller to create a flow of fluid. E...read more

Jigs and fixtures are devices used to hold and guide workpieces during manufacturing processes.

• Jigs are used to guide and control the cutting or machining tools.

• Fixtures are used to hold the workpiece in place during the manufacturing process.

• They increase production efficiency and accuracy while reducing costs.

• Examples include drill jigs, welding fixtures, and assembly fixtures.

Plant startup and shutdown procedure involves a series of steps to ensure safe and efficient operation.

• Before starting up the plant, conduct a thorough inspection of equipment and systems.

• Ensure all necessary permits and clearances are obtained before startup.

• Follow a specific sequence for starting up different units or sections of the plant.

• Monitor and adjust process parameters during startup to ensure smooth operation.

• During shutdown, gradually reduce production rates and s...read more

The battery working system involves the conversion of chemical energy into electrical energy to power devices.

• Batteries store chemical energy in the form of electrolytes and electrodes

• When a circuit is completed, chemical reactions occur to release electrons and generate electrical energy

• Different types of batteries include lead-acid, lithium-ion, and nickel-metal hydride

• Battery capacity is measured in ampere-hours (Ah) or watt-hours (Wh)

3 lvl IGBT has 3 layers of n-type and p-type semiconductors sandwiched between metal plates.

• IGBT stands for Insulated Gate Bipolar Transistor.

• It is a three-terminal power semiconductor device.

• The internal structure of 3 lvl IGBT consists of 3 layers of n-type and p-type semiconductors sandwiched between metal plates.

• The n-type and p-type layers are alternately stacked to form a p-n-p-n structure.

• The metal plates act as the gate and collector electrodes.

• The gate electrode is i...read more

Gating system is a network of channels that delivers molten metal to the mold cavity during casting.

• It consists of sprue, runner, gates, and risers.

• Sprue is the main channel that connects the pouring basin to the runner.

• Runner is a channel that connects the sprue to the gates.

• Gates are openings in the mold cavity that control the flow of molten metal.

• Risers are reservoirs that provide additional molten metal to compensate for shrinkage during solidification.

• The gating system ...read more

5S is a methodology for workplace organization and VSM is a tool for process improvement.

• 5S stands for Sort, Set in Order, Shine, Standardize, and Sustain

• 5S helps to improve efficiency, safety, and quality in the workplace

• VSM stands for Value Stream Mapping

• VSM is used to identify and eliminate waste in a process

• VSM helps to improve lead time, quality, and cost

• Both 5S and VSM are commonly used in Lean manufacturing

Types of pumps include centrifugal pumps, positive displacement pumps, and axial flow pumps.

• Centrifugal pumps: use a rotating impeller to increase the pressure of a fluid.

• Positive displacement pumps: move fluid by trapping a fixed amount and forcing it through the discharge.

• Axial flow pumps: move fluid parallel to the impeller shaft.

• Examples: Centrifugal pump - water pump, Positive displacement pump - diaphragm pump, Axial flow pump - propeller pump