40+ new Product Development Engineer Interview Questions and Answers

Surface finish symbols are used to indicate the type of surface finish required for a part.

• Surface finish symbols are typically represented by a series of lines, circles, and triangles.

• The symbols are used to indicate the type of surface finish required for a part, such as roughness, waviness, or lay.

• Examples of surface finish symbols include Ra for roughness average, Rz for roughness depth, and W for waviness.

1st and 3rd angle projection symbols are used in engineering drawings to indicate the orientation of the object being depicted.

• 1st angle projection symbol is a triangle with the number '1' inside and is used in Europe and Asia.

• 3rd angle projection symbol is a triangle with the number '3' inside and is used in North America.

• The symbol is usually placed in the lower right-hand corner of the drawing.

• The symbol indicates the direction of the view and the position of the object in...read more

Draw orthographic projections of given isometric view.

• Identify the isometric view and its orientation

• Draw the front, top, and right views using the correct scale and proportions

• Ensure that all lines are parallel and dimensions are accurate

• Label each view with the appropriate dimensions and notes

• Check for any errors or inconsistencies

Bernoulli's theorem states that potential energy decreases as kinetic energy increases in a fluid flow.

• Bernoulli's theorem is based on the conservation of energy in a fluid flow.

• Potential energy is the energy possessed by a fluid due to its position or elevation.

• Kinetic energy is the energy possessed by a fluid due to its motion.

• As the velocity of a fluid increases, its kinetic energy increases and its potential energy decreases.

• This relationship is described by Bernoulli's e...read more

Relative humidity is the ratio of actual water vapor present in the air to the maximum amount of water vapor air can hold at a given temperature.

• Absolute humidity is the actual amount of water vapor present in the air.

• Saturation humidity is the maximum amount of water vapor air can hold at a given temperature.

• Relative humidity and absolute humidity are measured in percentage while saturation humidity is measured in grams per cubic meter.

• Relative humidity is affected by temper...read more

CC LED driver maintains constant current output while CV LED driver maintains constant voltage output.

• CC LED driver is used for high power LEDs and ensures uniform brightness.

• CV LED driver is used for low power LEDs and ensures longer lifespan.

• CC LED driver is more expensive than CV LED driver.

• CC LED driver is more efficient than CV LED driver.

• CC LED driver is used in applications where LED brightness needs to be maintained constant.

• CV LED driver is used in applications where...read more

I will follow a structured process to evaluate the impact of the change and ensure proper documentation and communication.

• Review the change request and assess its impact on the product design, cost, and schedule

• Evaluate the feasibility of the change and propose alternatives if necessary

• Document the change request and update relevant documents such as drawings, specifications, and BOMs

• Communicate the change to stakeholders such as manufacturing, quality, and suppliers

• Obtain ap...read more

PPAP (Production Part Approval Process) is a standardized process in the automotive industry to ensure suppliers meet quality standards.

• PPAP is a set of guidelines developed by the Automotive Industry Action Group (AIAG) to establish confidence in suppliers and their production processes.

• It involves submitting documentation such as design records, process flow diagrams, control plans, and measurement system analysis.

• PPAP is typically required by automotive OEMs before a new p...read more

I learned about materials science and engineering principles, including sustainable design and waste reduction.

• I learned about the properties and characteristics of different materials, including plastics, and how they can be designed for sustainability and recyclability.

• I also studied waste reduction strategies, such as designing products for disassembly and reuse, and using biodegradable materials.

• One solution to plastic waste is to promote the use of biodegradable plastics...read more

Plastics are synthetic materials made from polymers that can be molded into various shapes and forms.

• Plastics are widely used in manufacturing due to their versatility and durability.

• They are commonly used in packaging, construction, automotive, and electronics industries.

• Examples of plastics include polyethylene, polypropylene, PVC, and PET.

• Plastics can be recycled, but not all types are recyclable.

• Plastics can have negative environmental impacts if not disposed of properly.

Gear ratio is the ratio of the number of teeth on the driven gear to the number of teeth on the driving gear.

• Count the number of teeth on the driving gear (gear attached to the motor) and the driven gear (gear attached to the load)

• Divide the number of teeth on the driven gear by the number of teeth on the driving gear to get the gear ratio

• For example, if the driving gear has 20 teeth and the driven gear has 40 teeth, the gear ratio is 2:1

PFD stands for Process Flow Diagram, which is a visual representation of the steps involved in a process.

• PFDs are used to understand the flow of a process and identify potential areas for improvement.

• They typically include equipment, materials, and information flow.

• PFDs are essential in new product development to ensure efficient and effective processes.

• Examples of PFDs include diagrams showing the steps involved in manufacturing a new product or the flow of information in a ...read more

PFMEA stands for Process Failure Mode and Effects Analysis, a method used to identify and prioritize potential failure modes in a process.

• PFMEA is a systematic approach to identifying and preventing potential failures in a manufacturing or development process.

• It involves analyzing each step of the process to determine potential failure modes, their effects, and the likelihood of occurrence.

• Risk priority numbers (RPN) are calculated to prioritize which failure modes should be ...read more

I have 3 years of experience in mobile manufacturing.

• Worked for 3 years in a mobile manufacturing company

• Experience in designing and developing new mobile products

• Knowledge of manufacturing processes and quality control in mobile industry

APQP is a structured approach to product development that ensures customer satisfaction through effective planning and risk management.

• APQP involves cross-functional teams working together to identify and mitigate potential risks throughout the product development process.

• It includes five phases: planning, product design and development, process design and development, product and process validation, and launch, assessment, and feedback.

• APQP is commonly used in the automotive...read more

Yes, I am proficient in 3D modelling and drafting using software like SolidWorks and AutoCAD.

• Proficient in 3D modelling software like SolidWorks and AutoCAD

• Experienced in creating detailed drafts and models for new product development

• Ability to interpret technical drawings and specifications accurately

Surges occur at outdoor LED lighting due to various reasons.

• Lightning strikes

• Power fluctuations

• Switching of high-power equipment

• Faulty wiring

• Poor grounding

• Inadequate surge protection

• Environmental factors such as humidity and temperature changes

• Overloading of circuits

• Electromagnetic interference

• Voltage spikes from the power grid

• Inrush current during startup

• Design flaws in the LED driver circuitry

Shrinkage value of a material refers to the amount by which the material contracts or shrinks during the cooling process after being molded or formed.

• Shrinkage value is typically expressed as a percentage of the original size of the material.

• It is an important factor to consider in manufacturing processes, especially in injection molding and casting.

• Different materials have different shrinkage values, so it is crucial to account for this when designing molds or parts.

• For exam...read more

Pulley provides mechanical advantage by reducing the amount of force required to lift a load.

• A pulley system can have multiple pulleys to increase mechanical advantage

• The mechanical advantage of a pulley is equal to the number of supporting ropes or cables

• Pulleys can change the direction of the force applied to lift a load

• Examples of pulleys include cranes, elevators, and flagpoles

Tolerances and fits are important in product development. Tolerances refer to the allowable variation in dimensions, while fits describe the degree of interference between mating parts.

• Tolerances can be classified as either unilateral or bilateral

• Fits can be classified as clearance, interference, or transition

• Examples of fits include press fit, slip fit, and force fit

LED flickering can be resolved by checking power supply, using proper dimmer, and selecting high-quality LED bulbs.

• Check power supply for voltage fluctuations

• Use a proper dimmer that is compatible with LED bulbs

• Select high-quality LED bulbs that are designed to work with dimmers

• Ensure proper grounding of the circuit

• Avoid using too many LED bulbs on a single circuit

• Consider using an LED driver to regulate the voltage

• Check for loose connections or damaged wiring

APQP stands for Advanced Product Quality Planning, a structured method for developing and introducing new products.

• APQP is a quality framework used in the automotive industry to ensure that products meet customer requirements.

• It involves defining the project scope, creating a cross-functional team, and developing a detailed plan.

• APQP includes activities such as design and process FMEAs, control plans, and production part approval.

• The goal of APQP is to prevent defects and red...read more

PPAP Submission level is a process of ensuring that the supplier's production process meets the customer's requirements.

• PPAP stands for Production Part Approval Process

• It is a standardized process used in the automotive industry

• PPAP submission level is the level of documentation required for a supplier to demonstrate that their production process is capable of meeting the customer's requirements

• There are five levels of PPAP submission, with level 1 being the least stringent a...read more

I am comfortable with CAD software like SolidWorks and AutoCAD, as well as simulation software like ANSYS.

• CAD software like SolidWorks and AutoCAD

• Simulation software like ANSYS

CAD software, simulation tools, project management software

• CAD software like SolidWorks for designing

• Simulation tools like ANSYS for testing designs

• Project management software like Jira for tracking progress

Casting is a manufacturing process where a liquid material is poured into a mold and allowed to solidify. Casting defects can occur due to various reasons.

• The liquid material is usually a metal or an alloy.

• The mold is made of a refractory material such as sand or ceramic.

• The mold is designed to have the desired shape of the final product.

• The liquid material is poured into the mold through a sprue.

• The material solidifies and takes the shape of the mold.

• Casting defects can occu...read more

The rough estimate of 100w and 50w FL depends on various factors such as the type of bulb, voltage, and lumens.

• The type of bulb used affects the wattage and lumens produced.

• The voltage supplied also affects the wattage and lumens produced.

• The lumens produced by a 100w and 50w FL bulb can vary depending on the manufacturer.

• A rough estimate for a 100w FL bulb is around 1600-1800 lumens.

• A rough estimate for a 50w FL bulb is around 800-900 lumens.

NPI stands for New Product Introduction, the process of bringing a new product to market.

• NPI involves concept development, design, testing, manufacturing, and launch of a new product.

• It includes market research, competitive analysis, and customer feedback to ensure product success.

• NPI aims to minimize time to market, reduce costs, and maximize product quality.

• Examples of NPI include the launch of a new smartphone model or a medical device.

• Effective NPI processes can lead to i...read more

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

• It is a widely used manufacturing process in various industries.

• The molten material is typically a thermoplastic or thermosetting polymer.

• The material is injected into a mold cavity under high pressure.

• Once cooled and solidified, the mold is opened, and the part is ejected.

• Injection molding allows for the production of complex and precise parts with high efficiency.

• Exam...read more

APQP has five phases: Planning, Design and Development, Process Design and Development, Product and Process Validation, and Launch, Assessment and Feedback.

• APQP stands for Advanced Product Quality Planning

• The Planning phase involves defining the project scope, identifying customer needs, and creating a project plan

• The Design and Development phase involves creating product and process designs, and conducting risk assessments

• The Process Design and Development phase involves dev...read more

I am familiar with various software programs used in product development such as CAD, CAM, and simulation software.

• Proficient in CAD software such as SolidWorks and AutoCAD

• Experience with CAM software like Mastercam and Fusion 360

• Familiarity with simulation software such as ANSYS and COMSOL

• Knowledge of programming languages like Python and MATLAB for automation and data analysis

The dimensions and tolerances information for a product are critical for ensuring proper fit and function.

• Dimensions refer to the measurements of a part or product, such as length, width, and height.

• Tolerances indicate the allowable deviation from the specified dimensions, ensuring parts fit together properly.

• Accurate dimensions and tolerances are essential for successful product development and manufacturing.

• Examples: A part may have a length dimension of 10 cm with a tolera...read more

Surge protection device installation involves proper grounding and connection to electrical panels.

• Ensure proper grounding of the device

• Connect the device to the electrical panel

• Follow manufacturer's instructions for installation

• Test the device after installation to ensure it is functioning properly

Equipment should be handled with care and following proper procedures.

• Always follow manufacturer's instructions for handling and maintenance.

• Use appropriate personal protective equipment when handling equipment.

• Store equipment in a safe and secure location when not in use.

• Regularly inspect equipment for any signs of damage or wear.

• Train employees on proper handling procedures to prevent accidents or damage.

Privacy company rool is a company that prioritizes protecting user data and privacy in their products and services.

• Focus on data encryption and security measures

• Implement strict privacy policies and guidelines

• Regularly update privacy features to adapt to changing regulations

• Provide transparency to users about data collection and usage

• Offer options for users to control their privacy settings

• Examples: DuckDuckGo, ProtonMail, Signal

MIM technology stands for Metal Injection Molding, a manufacturing process that combines the design flexibility of plastic injection molding with the strength and durability of metal materials.

• MIM technology involves mixing metal powders with a binder material to create a feedstock

• The feedstock is then injected into a mold cavity to form the desired shape

• After molding, the part is heated to remove the binder and sinter the metal powders together

• MIM technology is commonly used...read more

Documents and PF details can be shared upon request.

• Documents such as project plans, design specifications, test reports, etc. can be provided.

• PF details including contribution amounts, investment options, and withdrawal procedures can be shared.

• It is important to ensure confidentiality and compliance with data protection regulations when sharing such information.

APQP and PPAP are quality management systems used in product development.

• APQP stands for Advanced Product Quality Planning and is a framework used to develop new products with a focus on quality.

• PPAP stands for Production Part Approval Process and is a set of guidelines used to ensure that suppliers provide parts that meet the required specifications.

• APQP and PPAP are commonly used in the automotive industry, but can be applied to any industry that requires quality management...read more

Mold temp refers to the temperature of the mold used in the injection molding process.

• Mold temp is a critical factor in determining the quality and properties of the final product.

• It affects the cooling rate of the molten material inside the mold.

• Maintaining proper mold temp helps in achieving consistent part dimensions and minimizing defects.

• Examples: High mold temp can lead to longer cooling times but better surface finish, while low mold temp can cause warping or sink mark...read more

I would analyze the components to determine their compatibility, functionality, and potential improvements for the project.

• Analyze each component's specifications and requirements

• Identify any potential compatibility issues

• Evaluate the functionality of each component

• Brainstorm potential improvements or optimizations

• Consider cost and time constraints for implementing changes

INDO-MIM Ltd is a leading global supplier of precision-engineered products using Metal Injection Molding (MIM) technology.

• Specializes in Metal Injection Molding (MIM) technology

• Provides precision-engineered products

• Global supplier with a strong presence in the industry

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

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

• It helps ensure that parts fit together properly and function as intended.

• GD&T uses symbols such as concentricity, flatness, perpendicularity, and position to communicate design requirements.

• It is commonly used in industries ...read more

APQP, PPAP, and PFMEA are quality management tools used in product development.

• APQP (Advanced Product Quality Planning) is a framework used to plan and develop new products or processes.

• PPAP (Production Part Approval Process) is a process used to ensure that all parts used in a product meet the required specifications.

• PFMEA (Process Failure Mode and Effects Analysis) is a tool used to identify and mitigate potential failures in a product or process.

Creating a 3D model from a 2D design

• Start by identifying the dimensions and features of the 2D design

• Use software like AutoCAD or SolidWorks to create the 3D model

• Consider the material properties and manufacturing processes when modeling

A process flow diagram is a visual representation of the steps involved in a manufacturing process.

• Shows the sequence of steps in a process

• Includes inputs, outputs, and decision points

• Helps identify bottlenecks and inefficiencies

• Used for process optimization and troubleshooting