200+ Operator Interview Questions and Answers

The interview question covers topics related to measuring instruments such as micrometres, vernier calipers, gauges, and dial indicators.

• Least count of micrometres is the smallest measurement that can be read by the instrument.

• Vernier calipers are used to measure the internal and external dimensions of objects.

• Gauges are tools used to measure the thickness, diameter, or distance between two surfaces.

• Types of gauges include plug gauges, ring gauges, and snap gauges.

• To measure ...read more

Questions related to reactor types, distillation, heat transfer, fire safety, work permits, and plant processes.

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

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

• Vacuum distillation is used to separate compounds with high boiling points.

• Vacuum pumps are used to create a vacuum in a system.

• Exothermic reactions release heat, while endothermic reactions absorb heat.

• Heat transfer can o...read more

I follow a systematic approach to troubleshoot and solve the problem in the machine.

• I first identify the problem and its root cause

• Then I refer to the machine manual or seek help from colleagues

• I try to fix the problem myself if possible

• If not, I escalate the issue to the concerned department

• I ensure that the machine is not operated until the problem is resolved

The problems associated with balling include material sticking together, uneven size distribution, and issues with moisture content. Controlling dry or moist materials involves adjusting the composition and process parameters. Addressing issues from disturbed material in the balling disc requires quick adjustments and monitoring.

• Problems with balling include material sticking together, uneven size distribution, and issues with moisture content

• Control dry materials by adjustin...read more

The least count of measurement instruments like dial gauge, caliper, and micrometer and how to use them.

• Dial gauge typically has a least count of 0.01 mm and is used to measure small distances or thicknesses.

• Calipers usually have a least count of 0.02 mm and are used for measuring lengths and diameters.

• Micrometers have a least count of 0.01 mm and are used for precise measurements of small dimensions.

In this situation, I would first investigate the root cause of the moisture material report and balling disturbance before taking any action.

• Investigate the source of the moisture material report to determine if it is a recurring issue or a one-time occurrence.

• Check the equipment and processes involved in the balling process to identify any potential causes of disturbance.

• Consult with relevant team members or experts to gather more information and insights on the issue.

• Implem...read more

ETP plant is set up to treat industrial wastewater before releasing it into the environment. UASBR is a type of ETP.

• ETP plant is necessary to prevent pollution of water bodies

• UASBR stands for Upflow Anaerobic Sludge Blanket Reactor

• UASBR is a type of ETP that uses anaerobic bacteria to break down organic matter in wastewater

• Other types of ETP include activated sludge process, sequencing batch reactor, and membrane bioreactor

A balling disc is a tool used in the pelletizing process to create uniform pellets from powdered materials.

• A balling disc consists of a rotating pan with adjustable angles and a liquid binder spray system.

• To handle a balling disc effectively, operators should regularly monitor and adjust the disc speed, angle, and binder spray rate.

• Potential problems with a balling disc include uneven pellet size, low pellet strength, and excessive dust generation.

• Examples of handling potenti...read more

During line clearance for coating process, we should check for cleanliness, proper equipment setup, and adherence to safety protocols.

• Ensure the coating area is clean and free from any residue or contaminants.

• Verify that the coating equipment is properly set up and calibrated for the specific coating process.

• Check if all safety measures and protocols are followed, including the use of personal protective equipment (PPE) and proper ventilation.

• Inspect the coating materials and...read more

Titanium dioxide is commonly used as an opacifier in film coating.

• Titanium dioxide is a white pigment that provides opacity and whiteness to film coatings.

• It is widely used in industries such as pharmaceuticals, cosmetics, and food.

• Other opacifiers used in film coating include zinc oxide and calcium carbonate.

Phase sequence, phase voltage, line voltage, earthing, and power factor are all important electrical concepts.

• Phase sequence refers to the order in which the three phases of an AC power supply reach their maximum values.

• Phase voltage is the voltage measured across a single phase of an AC power supply.

• Line voltage is the voltage measured between any two phases of an AC power supply.

• Earthing is the process of connecting a conductor to the earth to prevent electric shock and pro...read more

As an operator in beverage filling machine, one must know the type of filler, the filling process, and how to handle breakdowns.

• Operators must be knowledgeable about the type of filler used in the machine.

• They should also be familiar with the filling process to ensure that the product is filled accurately and efficiently.

• In case of breakdowns, operators must know how to troubleshoot and fix the issue to minimize downtime.

• The job role of an operator in beverage filling machine...read more

Clinging of p type and c type is done by using appropriate cleaning solutions and techniques.

• For p type, RCA clean is used which involves cleaning with a mixture of hydrogen peroxide, ammonium hydroxide, and deionized water.

• For c type, piranha solution is used which involves cleaning with a mixture of sulfuric acid and hydrogen peroxide.

• Both types require proper handling and safety precautions due to the hazardous nature of the cleaning solutions.

• Cleaning should be followed b...read more

We fill various types of capsules based on the requirements of our clients.

• We fill both gelatin and vegetarian capsules.

• Capsules can be filled with powders, pellets, or liquids.

• We can fill capsules with different sizes and colors.

• We also offer customized printing on capsules.

• The types of capsules we fill depend on the needs of our clients.

The principle of a coating machine is to apply a thin layer of material onto a surface.

• Coating machines use various methods such as spraying, dipping, or rolling to apply the coating material.

• The coating material can be a liquid, powder, or a combination of both.

• The machine ensures uniform and controlled application of the coating material.

• Coating machines are used in various industries like automotive, electronics, and packaging.

• Examples of coating machines include spray coa...read more

When high or low grinding material report, I adjust the settings on the machine and check for any issues with the material.

• Check the settings on the machine for grinding material

• Adjust the settings accordingly to address the high or low report

• Inspect the material for any issues or abnormalities

• Make necessary adjustments to ensure proper grinding process

Experience is more necessary than an engineering degree.

• Experience helps in practical problem-solving and decision-making.

• Engineering degree provides theoretical knowledge and technical skills.

• Experience can compensate for lack of formal education.

• Employers often value experience over education.

• Combination of both education and experience is ideal.

A reboiler heats the bottom liquid of a distillation column, providing vapor for separation of components.

• Reboilers are essential for maintaining the temperature gradient in a distillation column.

• They convert liquid into vapor, which rises through the column for separation.

• Common types include kettle reboilers and thermosiphon reboilers.

• For example, in a crude oil distillation unit, reboilers help separate lighter fractions from heavier ones.

The question covers various topics related to pumps, valves, and chemical properties.

• pH is a measure of acidity or alkalinity of a solution.

• Tar density is the mass of tar per unit volume of a substance.

• Tar production process involves heating organic materials in the absence of air.

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

• Types of valves include ball, gate, globe, and check valves.

• NRV stands for Non-Return Valve, which allows fluid to flo...read more

Effective man management requires clear communication, delegation, motivation, and conflict resolution.

• Clear communication: Ensuring that expectations, goals, and feedback are communicated clearly to the team members.

• Delegation: Assigning tasks and responsibilities to the right individuals based on their skills and strengths.

• Motivation: Inspiring and motivating the team members to achieve their best performance.

• Conflict resolution: Addressing conflicts and disagreements among...read more

The carburetor is installed in gasoline-powered cars.

• Carburetors are not found in diesel-powered cars.

• Carburetors mix air and fuel for the engine to use.

• Modern cars typically use fuel injection instead of carburetors.

• Carburetors were commonly used in cars before the 1980s.

• Examples of cars with carburetors include the Ford Mustang and Chevrolet Camaro.

The least count of micrometres in a vernier caliper is typically 0.01 mm or 0.001 cm.

• The least count is the smallest measurement that can be read on the instrument.

• In a vernier caliper, the main scale typically has graduations of 1 mm or 0.1 cm.

• The vernier scale has 10 divisions that cover 9 main scale divisions, resulting in a least count of 0.01 mm or 0.001 cm.

Fundamental deviation of hole in BIS system can be indicated by specifying the tolerance zone and the position of the hole.

• Specify the tolerance zone for the hole based on the BIS system standards.

• Measure the actual position of the hole and compare it to the specified tolerance zone.

• If the actual position of the hole falls outside the tolerance zone, indicate it as a fundamental deviation.

The number of documents controlling component making varies depending on the complexity of the process.

• The number of documents can range from a few to dozens depending on the complexity of the component and the regulations that need to be followed.

• Examples of documents that may be involved include work instructions, standard operating procedures, quality control checklists, and safety protocols.

• The documents are designed to ensure consistency and quality in the manufacturing ...read more

A rack and pinion mechanism is used to convert linear motion of plunger to rotary motion of pointer in D.T.I.

• Rack and pinion mechanism consists of a gear (pinion) that meshes with a linear gear (rack) to convert linear motion into rotary motion.

• As the plunger moves linearly, it engages with the rack which in turn rotates the pinion, causing the pointer to move.

• This mechanism is commonly used in devices like dial indicators to accurately measure small distances.

• The rack and pi...read more

The trolley travels a distance of 18.50 meters at a speed of 70 meters per minute.

• The trolley covers a distance of 18.50 meters.

• It travels at a speed of 70 meters per minute.

• The trolley can be measured in terms of distance covered and speed.

Distillation columns separate mixtures based on differences in boiling points using various designs and techniques.

• Continuous Distillation: Used in large-scale operations, e.g., crude oil refining.

• Batch Distillation: Suitable for smaller quantities, e.g., producing essential oils.

• Fractional Distillation: Separates components with close boiling points, e.g., separating ethanol from water.

• Vacuum Distillation: Lowers boiling points by reducing pressure, e.g., for heat-sensitive ...read more