60+ Production & Quality Engineer Interview Questions and Answers

Kaizen is a continuous improvement philosophy, 8D methodology is a problem-solving approach, and measuring instruments used in manufacturing industries include calipers, micrometers, and gauges.

• Kaizen is a Japanese term meaning 'change for the better' and focuses on continuous improvement in all aspects of an organization.

• 8D methodology is a problem-solving approach that consists of eight steps to identify, analyze, and resolve problems.

• Measuring instruments used in manufactu...read more

Implemented quality control procedures in a project for improving product reliability.

• Identified critical components and their failure modes

• Developed test plans and procedures to validate component reliability

• Implemented statistical process control to monitor production process

• Conducted root cause analysis and implemented corrective actions

• Reduced product failure rate by 30% and improved customer satisfaction

To ensure quality, a production & quality engineer can implement various measures such as conducting inspections, implementing quality control processes, and using statistical analysis.

• Conduct regular inspections to identify any defects or issues in the production process.

• Implement quality control processes to ensure that products meet the required standards.

• Use statistical analysis techniques to monitor and improve product quality.

• Establish clear quality objectives and commu...read more

I investigate production flaws by analyzing data, observing processes, and conducting tests.

• Collect and analyze data on the production process

• Observe the production process to identify potential flaws

• Conduct tests to confirm the cause of the flaw

• Collaborate with production team to develop solutions

• Implement solutions and monitor results

• Document findings and share with relevant stakeholders

The first law of thermodynamics states that energy cannot be created or destroyed, only transferred or converted.

• Energy is conserved in a closed system

• It can be transferred as heat or work

• The change in internal energy of a system is equal to the heat added to the system minus the work done by the system

• Example: When a gas expands and does work on its surroundings, the internal energy of the gas decreases

A battery is a device that stores chemical energy and converts it into electrical energy.

• Batteries consist of one or more electrochemical cells

• The chemical reactions inside the cells produce a flow of electrons, which can be harnessed as electrical energy

• Different types of batteries include alkaline, lithium-ion, and lead-acid

• Batteries are commonly used in portable electronic devices, vehicles, and backup power systems

Ppap, fmeam, qc tool, capa, mistakes proofing, process audit, product audit are all important concepts in production and quality engineering.

• PPAP (Production Part Approval Process) is a standardized process used in the automotive industry to ensure that suppliers meet the required quality standards for their parts.

• FMEA (Failure Mode and Effects Analysis) is a systematic approach to identify and prioritize potential failures in a product or process, and take preventive actions...read more

Tolerance is the allowable limit or variation in a dimension, gear is a mechanical component used to transmit motion, and joints are used to connect one shaft to another for power transmission.

• Tolerance is the permissible limit of variation in a dimension to ensure proper fit and function

• Gears are mechanical components with teeth that mesh together to transmit motion and power

• Joints are used to connect one shaft to another to transmit power efficiently and smoothly

An induction motor is an AC electric motor in which the electric current in the rotor is produced by electromagnetic induction from the magnetic field of the stator winding.

• Induction motors are widely used in industrial applications due to their reliability and low cost.

• They are classified into two types: single-phase induction motors and three-phase induction motors.

• Single-phase induction motors are used in small appliances, while three-phase induction motors are used in hea...read more

I have used several development tools throughout my career.

• I have experience with IDEs such as Eclipse, Visual Studio, and IntelliJ IDEA.

• I have used version control systems like Git and SVN.

• I am familiar with build tools like Maven and Gradle.

• I have worked with testing frameworks such as JUnit and Selenium.

• I have used debugging tools like GDB and WinDbg.

• I have experience with performance profiling tools like JProfiler and YourKit.

5S is a workplace organization method that aims to improve efficiency and productivity.

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

• It involves organizing and cleaning the workplace to eliminate waste and improve safety.

• Drawing specification and symbols are important in manufacturing to ensure consistency and accuracy.

• Understanding these symbols and specifications is crucial for a production cum quality engineer.

Piece weight can be found by weighing the object on a scale. Least count of vernier caliper is the smallest measurement it can make.

• To find piece weight, place the object on a scale and record the weight

• The least count of a vernier caliper is the smallest measurement it can make

• For example, if the least count is 0.1mm, the caliper can measure up to 0.1mm accuracy

A project quality plan is important to ensure that the project meets the required quality standards and customer expectations.

• Helps to identify quality objectives and requirements

• Defines quality control and assurance activities

• Ensures compliance with industry standards and regulations

• Reduces the risk of defects and rework

• Improves customer satisfaction and trust

• Provides a framework for continuous improvement

• Helps to manage project resources effectively

Hardness is a material's resistance to deformation, properties vary based on material composition, grade indicates quality level, and relative information includes testing methods.

• Hardness is a material's ability to resist deformation, typically measured using scales like Rockwell or Brinell.

• Properties of a material include its mechanical, thermal, electrical, and chemical characteristics.

• Grade refers to the quality level of a material, with higher grades indicating better pe...read more

Parallity and perpendicularity can be checked using precision measuring tools and techniques.

• Use precision measuring tools such as calipers, micrometers, or height gauges to measure the dimensions of the object.

• For checking parallelity, measure the distance between two parallel surfaces at multiple points and ensure they are consistent.

• For checking perpendicularity, measure the angle between two surfaces that should be perpendicular and compare it to the desired angle.

• Utilize...read more

Determining salary expectations in our company

• Research the industry standards for salaries in the production and quality engineering field

• Consider your level of experience, education, and skills

• Take into account the company's size, location, and financial stability

• Discuss salary expectations during the interview process

• Negotiate based on your value and contributions to the company

Fatigue material properties refer to the characteristics of a material under repeated or cyclic loading.

• Fatigue strength: The maximum stress a material can withstand for a specified number of cycles before failure.

• Endurance limit: The stress level below which a material can endure an infinite number of cycles without failure.

• Fatigue life: The number of cycles a material can withstand before failure.

• Fatigue crack growth rate: The rate at which cracks propagate in a material un...read more

A furnace is a device used for heating purposes. There are different types of furnaces such as electric, gas, and oil.

• Furnace is a heating device used to generate heat for various applications.

• Types of furnaces include electric, gas, and oil.

• Furnaces are commonly used in industries for processes like metal smelting and glass making.

The value of production creativity lies in its ability to drive innovation, improve efficiency, and enhance product quality.

• Production creativity leads to the development of new and innovative products.

• It helps in finding creative solutions to production challenges, leading to improved efficiency.

• Creative production processes can result in higher quality products.

• Incorporating creative ideas in production can differentiate a company from its competitors.

• Creative approaches ca...read more

Diode, resistance, thermistor, and inductor are all different types of electronic components.

• A diode is a two-terminal electronic component that allows current to flow in only one direction.

• Resistance is the opposition to the flow of electric current.

• A thermistor is a type of resistor whose resistance changes significantly with temperature.

• An inductor is a passive electronic component that stores energy in a magnetic field when electric current flows through it.

Arduino is an open-source electronics platform based on easy-to-use hardware and software.

• Arduino is used for prototyping and creating interactive electronic projects

• It can be used for home automation, robotics, and IoT applications

• Arduino boards can be programmed using the Arduino IDE

• Arduino has a large community and library of pre-built code and projects

• Examples of Arduino projects include a smart thermostat, a robot arm, and a weather station

CNC stands for Computer Numerical Control, a technology used in manufacturing to control machining tools and 3D printers.

• CNC machines are programmed with a specific set of instructions, allowing for precise and automated manufacturing processes.

• They can be used for cutting, drilling, milling, and other processes in various materials such as metal, plastic, and wood.

• CNC machines are commonly used in industries like aerospace, automotive, and electronics for high-precision and ...read more

The operation and mechanical aspects of a reheating furnace are crucial for production and quality control.

• Ensure all components of the reheating furnace are functioning properly to maintain consistent heating temperatures.

• Regularly inspect and maintain the mechanical parts of the furnace to prevent breakdowns and ensure efficiency.

• Monitor the operation of the furnace to optimize heating processes and minimize energy consumption.

• Implement quality control measures to ensure th...read more

A lever gauge is used to measure the thickness of objects by applying pressure with a lever arm.

• Place the object to be measured between the anvils of the lever gauge.

• Use the lever arm to apply pressure on the object until it is firmly held between the anvils.

• Read the measurement displayed on the gauge to determine the thickness of the object.

• Ensure the gauge is calibrated properly for accurate measurements.

Managing transport service involves planning, organizing, and monitoring transportation activities to ensure efficient and reliable delivery.

• Develop a transportation plan based on customer requirements and available resources

• Coordinate with suppliers, carriers, and logistics teams to ensure timely pickup and delivery

• Implement quality control measures to ensure product integrity during transportation

• Monitor transportation performance and address any issues or delays

• Optimize ro...read more

Cylindricity refers to how closely a cylinder's surface conforms to a perfect cylinder, while circularity refers to how closely a circle's boundary conforms to a perfect circle.

• Cylindricity is a 3D form tolerance that controls the overall form of a cylinder, including straightness, roundness, and taper.

• Circularity is a 2D form tolerance that controls the roundness of a circle, ensuring that all points on the circle are equidistant from the center.

• Cylindricity is used for cyli...read more

The degree of parameter structural condition refers to the level of quality and integrity of the parameters used in a production process.

• The degree of parameter structural condition is crucial for ensuring the quality and reliability of the production process.

• It involves evaluating the accuracy, precision, and consistency of the parameters used.

• Examples include checking the calibration of measuring instruments, verifying the accuracy of temperature and pressure sensors, and e...read more

Different welding types used in industries include MIG, TIG, stick, and spot welding.

• MIG (Metal Inert Gas) welding uses a wire electrode and a shielding gas to join metals.

• TIG (Tungsten Inert Gas) welding uses a non-consumable tungsten electrode and a shielding gas.

• Stick welding, also known as Shielded Metal Arc Welding (SMAW), uses a flux-coated electrode.

• Spot welding is used for joining two or more metal sheets together at localized points.

Confidential sites moments refer to critical incidents or events that occur at sensitive or restricted locations.

• Confidential sites moments are important events that happen at locations with restricted access or sensitive information.

• These moments may involve security breaches, equipment failures, or other critical incidents that require immediate attention.

• Examples include a data breach at a secure government facility, a safety incident at a nuclear power plant, or a quality...read more

QC stands for Quality Control. The 7 QC tools are a set of techniques used to identify and solve quality-related problems in production processes.

• QC is the process of ensuring that products or services meet specified requirements and standards.

• The 7 QC tools are: Pareto Chart, Cause and Effect Diagram, Check Sheet, Control Chart, Histogram, Scatter Diagram, and Stratification.

• These tools help in analyzing data, identifying root causes of defects, and implementing corrective a...read more

Product quality can be controlled through implementing quality control processes, conducting regular inspections, using quality management systems, and continuous improvement efforts.

• Implementing quality control processes to ensure products meet specifications and standards

• Conducting regular inspections at various stages of production to identify and address any quality issues

• Utilizing quality management systems such as ISO standards to establish and maintain quality processe...read more

Increasing productivity can be achieved through efficient processes, employee training, automation, and continuous improvement.

• Implement lean manufacturing principles to streamline processes

• Invest in employee training and development to enhance skills and knowledge

• Utilize automation and technology to eliminate manual tasks and improve efficiency

• Encourage a culture of continuous improvement to identify and address inefficiencies

• Set clear goals and targets to motivate employees...read more

A cyclo converter is a type of power electronic circuit that converts AC power to variable frequency AC power.

• Converts AC power to variable frequency AC power

• Used in applications where variable speed control is required

• Consists of multiple thyristors arranged in a specific configuration

• Commonly used in industries like steel rolling mills and cement kilns

A DFT meter is a device used to measure the thickness of a coating or film on a material surface.

• DFT stands for Dry Film Thickness

• It is commonly used in industries such as automotive, aerospace, and construction

• The meter uses magnetic induction or eddy current to measure the thickness of the coating

• The thickness measurement is important for ensuring the quality and durability of the material

• Examples of materials that can be measured with a DFT meter include paint, powder coat...read more

Manufacture is the process of making products by hand or machinery, while production involves the overall process of creating goods on a large scale.

• Manufacture is the physical process of creating products, while production includes planning, organizing, and managing the entire manufacturing process.

• Manufacture typically involves smaller scale operations, while production is focused on mass production.

• Manufacture may involve more customization and individual attention to deta...read more

The carbon percentage in mild steel typically ranges from 0.05% to 0.25%.

• Mild steel is a low carbon steel alloy.

• The carbon content affects the strength and hardness of the steel.

• Higher carbon content increases the hardness and strength of the steel.

• Lower carbon content improves the weldability and ductility of the steel.

• Examples of mild steel include ASTM A36 and SAE 1018.

Different types of welds include fillet welds, groove welds, plug welds, and slot welds.

• Fillet welds are used to join two surfaces at right angles, forming a triangular cross-section.

• Groove welds are used to join two pieces of metal along a groove or channel.

• Plug welds are used to fill a hole in one piece of metal with weld material.

• Slot welds are used to join two overlapping pieces of metal by welding through a slot in the top piece.

UPS provides backup power instantly during power outages, while inverters convert DC power to AC power.

• UPS stands for Uninterruptible Power Supply and provides instant backup power during power outages.

• Inverters convert DC power from batteries or solar panels to AC power for use in homes or businesses.

• UPS typically have a battery backup system, while inverters may or may not have a battery backup.

• UPS are commonly used for critical equipment like computers, servers, and medica...read more

High quality of production value is essential for ensuring customer satisfaction and competitiveness in the market.

• Implementing robust quality control measures to detect and prevent defects

• Continuous improvement initiatives to optimize production processes

• Investing in state-of-the-art equipment and technology

• Training and developing skilled workforce

• Establishing strong supplier relationships to ensure quality raw materials

• Conducting regular audits and inspections to maintain q...read more

8D problem-solving method is a structured approach to identify, correct, and prevent recurring problems.

• 1. Define the problem: Clearly state the issue and its impact.

• 2. Establish a team: Form a cross-functional team to work on the problem.

• 3. Develop an interim containment action: Implement a temporary solution to prevent further issues.

• 4. Identify the root cause: Use tools like 5 Whys to determine the underlying cause.

• 5. Develop a permanent corrective action: Implement a long...read more

RPN in SPC stands for Risk Priority Number, a calculation used in Six Sigma to prioritize potential failure modes based on severity, occurrence, and detection.

• RPN is calculated by multiplying the severity, occurrence, and detection ratings of a potential failure mode.

• It helps in identifying high-risk failure modes that need immediate attention in order to improve quality.

• For example, if a failure mode has a severity rating of 5, occurrence rating of 3, and detection rating of...read more

The least count of vernier calliper is the smallest measurement that can be read on the scale.

• The least count is determined by dividing the smallest division on the main scale by the number of divisions on the vernier scale.

• For example, if the smallest division on the main scale is 0.1 cm and there are 10 divisions on the vernier scale, the least count would be 0.01 cm.

• The least count is important for accurate measurements and should be considered when selecting a measuring t...read more

My strong points include attention to detail, problem-solving skills, and ability to work well under pressure.

• Attention to detail: I have a keen eye for spotting errors and ensuring quality standards are met.

• Problem-solving skills: I am able to analyze complex issues and come up with effective solutions.

• Ability to work well under pressure: I can remain calm and focused in high-pressure situations, ensuring tasks are completed efficiently.

Manufacturing involves the production of goods through the use of labor, machines, tools, and chemical or biological processing.

• Manufacturing processes can include casting, molding, cutting, and assembling of materials.

• Quality control is essential in manufacturing to ensure products meet standards and specifications.

• Efficient production planning and scheduling are crucial for optimizing manufacturing operations.

• Continuous improvement initiatives such as Lean manufacturing and...read more

To handle the problem, it is important to identify the root cause, develop a plan, implement corrective actions, and monitor the effectiveness of the solution.

• Identify the root cause of the problem through data analysis and investigation.

• Develop a plan to address the problem, including setting objectives and defining actions.

• Implement corrective actions, ensuring proper communication and coordination with relevant stakeholders.

• Monitor the effectiveness of the solution through...read more

DT stands for Destructive Testing, which involves damaging a sample to understand its properties. NDT stands for Non-Destructive Testing, which allows testing without damaging the sample.

• DT involves damaging the sample to understand its properties

• NDT allows testing without damaging the sample

• Examples of NDT methods include ultrasonic testing, radiographic testing, and magnetic particle testing

Quality and production are closely related as ensuring quality in production processes leads to higher efficiency, lower costs, and customer satisfaction.

• Quality control measures can improve production efficiency by reducing defects and rework.

• Implementing quality standards can lead to cost savings by minimizing waste and improving overall process effectiveness.

• Ensuring high quality products can result in increased customer satisfaction and loyalty, leading to repeat business...read more