100+ Production Engineer Interview Questions and Answers for Freshers

Switches are used instead of relays in some domestic applications due to their smaller size, lower cost, and faster response time.

• Switches are smaller in size compared to relays, making them more suitable for compact domestic appliances.

• Switches are generally less expensive than relays, making them a cost-effective choice for domestic applications.

• Switches have a faster response time compared to relays, allowing for quicker operation in domestic appliances.

• Examples of domesti...read more

The injection time reciprocating screw moves forward, and after injection, the screw moves backward. NRV stands for Non-Return Valve.

• During the injection time, the reciprocating screw moves in the forward direction.

• After injection, the screw moves in the backward direction.

• NRV stands for Non-Return Valve.

The electrode used in MIG welding is a consumable wire electrode.

• MIG welding stands for Metal Inert Gas welding.

• The electrode is continuously fed through a welding gun and melts to form the weld.

• The wire electrode is made of the same material as the base metal being welded.

• The shielding gas used in MIG welding protects the weld from atmospheric contamination.

• Common types of wire electrodes include ER70S-6 for mild steel and ER308L for stainless steel.

Explaining the difference between 1st and 3rd angle projection and drawing views on paper.

• 1st angle projection is commonly used in Europe and Asia, while 3rd angle projection is used in North America.

• In 1st angle projection, the object is placed in front of the viewing plane, while in 3rd angle projection, the object is placed behind the viewing plane.

• To draw views on paper, first determine the orientation of the object and the viewing plane, then project the object onto the ...read more

Process Control

• Process control is my favorite subject in chemical engineering.

• I enjoy studying the principles and techniques used to control and optimize chemical processes.

• I find it fascinating how process control systems can improve efficiency, safety, and product quality.

• One example of process control is the use of feedback loops to maintain desired operating conditions in a chemical reactor.

• I also appreciate the importance of process control in industries such as oil refi...read more

Manual welding is done by a human operator while robotics welding is done by a machine.

• Manual welding requires a skilled operator to control the welding process while robotics welding is automated.

• Robotics welding is faster and more precise than manual welding.

• Manual welding is more flexible and can be used in a wider range of applications while robotics welding is best suited for high-volume production.

• Robotics welding can be programmed to perform complex welds that would be...read more

Metals are elements that have high electrical conductivity, luster, and malleability.

• Metals are typically solid at room temperature, except for mercury which is a liquid.

• Common types of metals include iron, copper, aluminum, gold, silver, and zinc.

• Metals can be classified as ferrous or non-ferrous based on their iron content.

• The chemical composition of metals varies depending on the specific element, but they all have a metallic bond.

• Metals are widely used in manufacturing, c...read more

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Vernier caliper is used for precise measurements of length, while multimeter is used for measuring electrical quantities.

• Vernier caliper is used to measure the dimensions of objects with high accuracy.

• It consists of a main scale and a sliding vernier scale, allowing for precise measurements.

• Vernier calipers are commonly used in manufacturing, engineering, and scientific applications.

• For example, they can be used to measure the diameter of a shaft or the thickness of a sheet.

• M...read more

Yes, I know the manufacturing procedure of relays.

• Relays are electromechanical devices used to control the flow of electricity in a circuit.

• The manufacturing procedure involves several steps such as designing, prototyping, testing, and mass production.

• Designing includes selecting the appropriate materials, determining the specifications, and creating the circuit diagram.

• Prototyping involves creating a working model to test the functionality and performance of the relay.

• Testin...read more

The least count of vernier caliper is 0.02 mm and that of micrometer is 0.01 mm.

• Least count of vernier caliper is 0.02 mm

• Least count of micrometer is 0.01 mm

• Least count is the smallest measurement that can be read on the scale

• It is important to know the least count for accurate measurements

Yes, epoxy is commonly used in relays for its insulating and adhesive properties.

• Epoxy is a type of resin that can be used as an adhesive or coating.

• In relays, epoxy is often used to encapsulate and protect the internal components.

• It provides insulation and helps to prevent moisture or dust from entering the relay.

• Epoxy can also improve the mechanical strength and stability of the relay.

• For example, epoxy is used in automotive relays to ensure reliable operation in harsh envi...read more

Thermodynamics is the study of energy and its transformations in various forms of matter.

• Thermodynamics is used in the design and optimization of engines, power plants, refrigeration systems, and other devices that involve energy transfer.

• It is also used in the study of chemical reactions and the behavior of materials at high temperatures and pressures.

• Thermodynamics helps in understanding the properties of materials and their phase transitions.

• It is used in the development o...read more

TIG welding uses a tungsten electrode to create a precise and clean weld, while MIG welding uses a consumable wire electrode and shielding gas.

• TIG welding is slower but produces higher quality welds with less spatter and distortion.

• MIG welding is faster and better suited for thicker materials and high-volume production.

• TIG welding requires more skill and experience, while MIG welding is easier to learn and use.

• TIG welding is commonly used for aerospace, automotive, and precis...read more

A relay is an electrically operated switch that uses an electromagnet to mechanically control the switching action.

• Relays are used to control high power circuits with low power signals.

• They can be used to control motors, lights, and other electrical devices.

• Relays have an input coil that generates a magnetic field when current flows through it.

• This magnetic field attracts a movable armature, which closes or opens the switch contacts.

• Relays can have multiple sets of contacts, ...read more

Factors to consider when designing a heat exchanger

• Type of fluid being used

• Flow rate and pressure drop requirements

• Temperature range and heat transfer rate

• Material compatibility and corrosion resistance

• Space constraints and installation considerations

Cutting tools are made of various materials depending on the application.

• High-speed steel (HSS) is commonly used for general-purpose cutting tools.

• Carbide is used for cutting hard materials like steel and titanium.

• Ceramics are used for high-speed cutting of cast iron and other hard materials.

• Diamond is used for cutting non-ferrous materials like glass and ceramics.

• Cobalt steel is used for cutting stainless steel and other high-temperature alloys.

Feed speed refers to the rate at which the cutting tool moves along the workpiece, while cutting speed refers to the speed at which the workpiece rotates or moves relative to the cutting tool.

• Feed speed is measured in units of distance per time, such as inches per minute or millimeters per second.

• Cutting speed is measured in units of surface speed, such as feet per minute or meters per second.

• Feed speed determines how quickly the cutting tool engages with the workpiece.

• Cuttin...read more

Commonly used sheet-metal assembly processes include welding, riveting, and adhesive bonding.

• Welding: Joining metal parts by melting and fusing them together, commonly used methods include spot welding, TIG welding, and MIG welding.

• Riveting: Joining metal parts using mechanical fasteners called rivets, which are inserted through holes and then deformed to hold the parts together.

• Adhesive bonding: Joining metal parts using specialized adhesives that create a strong bond betwee...read more

Basic guidelines for sheet metal fabrication include material selection, design considerations, and proper tooling and equipment.

• Choose the appropriate material for the desired application, considering factors such as strength, corrosion resistance, and cost.

• Design the sheet metal part with proper dimensions, tolerances, and features to ensure manufacturability and functionality.

• Consider bend radius, hole sizes, and edge treatments to avoid cracking, distortion, or sharp edge...read more

The pressure required depends on the height of the liquid column and its density.

• The pressure required is directly proportional to the height of the liquid column.

• The pressure required is also affected by the density of the liquid.

• The pressure can be calculated using the formula P = ρgh, where P is pressure, ρ is density, g is acceleration due to gravity, and h is height of the liquid column.

• The pump should be able to provide a pressure greater than the calculated value to ov...read more

I approach problems by analyzing the root cause, brainstorming solutions, and implementing the best option.

• Identify the root cause of the problem

• Brainstorm potential solutions

• Evaluate and select the best option

• Implement the solution and monitor for effectiveness

• Continuously improve the process to prevent future problems

Relays are used in various real-time applications for controlling electrical circuits.

• Industrial automation: Relays are used to control motors, pumps, and other industrial equipment.

• Power distribution: Relays are used in power grids to control the flow of electricity and protect against overloads.

• Automotive industry: Relays are used in vehicles for controlling headlights, wipers, and other electrical systems.

• Telecommunications: Relays are used in telephone exchanges to route ...read more

Mechanical engineering is a branch of engineering that deals with the design, analysis, and manufacturing of mechanical systems.

• It involves the study of mechanics, thermodynamics, materials science, and structural analysis.

• Mechanical engineers design and develop machines, tools, and equipment for various industries.

• They also work on improving the performance and efficiency of existing mechanical systems.

• Examples of mechanical systems include engines, turbines, robots, and HVA...read more

Pressure is the force exerted on a surface per unit area.

• Pressure is a measure of how much force is applied to a given area.

• It is calculated by dividing the force applied by the area over which it is distributed.

• Pressure can be expressed in various units such as pascals, pounds per square inch (psi), or atmospheres.

• Examples of pressure include the air pressure in a tire, the water pressure in a pipe, or the blood pressure in the human body.

Fertilizers and pesticides are substances used in the agriculture industry to enhance plant growth and protect crops from pests and diseases.

• Fertilizers are substances that provide essential nutrients to plants, promoting their growth and improving crop yield.

• Pesticides are chemicals used to control or eliminate pests, including insects, weeds, and diseases that can damage crops.

• Fertilizers can be organic (e.g., compost, manure) or synthetic (e.g., nitrogen, phosphorus, potas...read more

BOM stands for Bill of Materials. It is a list of all the components required to manufacture a final product.

• BOM includes the name, quantity, and description of each component.

• It helps in estimating the cost of production and managing inventory.

• BOM can be created manually or using software like ERP systems.

• Example: BOM for a car would include engine, wheels, seats, etc.

• BOM can also be used for maintenance and repair purposes.

Thermoplastics can be melted and reshaped multiple times, while thermosets undergo a chemical reaction during curing and cannot be reshaped.

• Thermoplastics can be melted and reshaped multiple times, while thermosets undergo a chemical reaction during curing and cannot be reshaped.

• Thermoplastics are typically used in products like plastic bags, bottles, and toys, while thermosets are used in products like car tires, electrical insulation, and adhesives.

• Thermoplastics have linea...read more

I have worked with a variety of electronics and electrical equipment including PLCs, motors, sensors, and control panels.

• Programmable Logic Controllers (PLCs)

• Motors

• Sensors

• Control Panels

Vapor space is present above the distillation tray.

• The vapor space is where the vapor from the boiling liquid accumulates.

• It is important to maintain a certain level of vapor space to prevent flooding of the tray.

• The height of the vapor space can be controlled by adjusting the reflux ratio.

• The vapor space can also be used for heat transfer by introducing a cooling medium.

• Examples of equipment present in the vapor space include demisters and mist eliminators.

5S is a methodology used to organize a workplace for efficiency and effectiveness. The 5 C's are key components of 5S: Sort, Set in order, Shine, Standardize, Sustain.

• Sort - separating necessary items from unnecessary items

• Set in order - arranging necessary items in a logical and efficient manner

• Shine - cleaning and maintaining the work area

• Standardize - establishing consistent procedures and practices

• Sustain - ensuring the 5S system is maintained over time

• Example: Sorting th...read more

Yes, electric vehicles are useful for the ecosystem.

• Electric vehicles produce zero tailpipe emissions, reducing air pollution and improving air quality.

• They help in reducing greenhouse gas emissions, contributing to the fight against climate change.

• Electric vehicles can be powered by renewable energy sources, further reducing their environmental impact.

• They promote energy independence by reducing reliance on fossil fuels.

• Electric vehicles have the potential to decrease noise ...read more

The future aspects of a Production Engineer include automation, advanced technologies, sustainability, and continuous improvement.

• Automation: The use of robotics and artificial intelligence to streamline production processes and increase efficiency.

• Advanced technologies: Integration of IoT, big data analytics, and machine learning to optimize production systems.

• Sustainability: Implementing eco-friendly practices and renewable energy sources to reduce environmental impact.

• Cont...read more

A relay is an electrically operated switch that uses an electromagnet to mechanically control the switching action.

• Relays are commonly used in electrical systems to control high-power devices with low-power signals.

• They consist of a coil, an armature, and a set of contacts.

• When the coil is energized, the armature moves and closes or opens the contacts, allowing or interrupting the flow of current.

• Relays are used in various applications such as automotive, industrial automatio...read more

Welding is a process of joining two or more metal parts by heating the surfaces to their melting points and allowing them to cool and fuse together. There are several types of arc welding.

• Arc welding uses an electric arc to melt the metal and create the bond.

• Shielded metal arc welding (SMAW) is the most common type of arc welding, also known as stick welding.

• Gas metal arc welding (GMAW) uses a wire electrode and a shielding gas to protect the weld from contamination.

• Flux-core...read more

Third angle method of projection is a technique used in engineering drawing to represent a 3D object in 2D space.

• In this method, the object is placed in the third quadrant and the observer is placed in the first quadrant.

• The projection plane is placed between the observer and the object.

• The object is projected onto the projection plane and the resulting image is viewed by the observer.

• This method is commonly used in Europe and Asia.

• It is the opposite of the first angle method...read more

A lathe machine is used to shape and cut metal or wood by rotating the workpiece against a cutting tool.

• A lathe machine is commonly used in manufacturing and woodworking industries.

• It can be used to create cylindrical shapes, such as screws or bolts.

• The machine rotates the workpiece while a cutting tool is applied to shape or cut the material.

• It can be operated manually or with computer numerical control (CNC) technology.

• Lathe machines can also be used for tasks like sanding,...read more

Four stroke engines have four distinct phases while two stroke engines have only two phases.

• Four stroke engines have separate intake, compression, power, and exhaust strokes.

• Two stroke engines combine intake and compression in one stroke, and power and exhaust in another stroke.

• Four stroke engines are more fuel efficient and produce less pollution compared to two stroke engines.

• Examples of four stroke engines include most cars, trucks, and motorcycles.

• Examples of two stroke e...read more

A CNC machine is a computer-controlled machine tool used for precision machining.

• CNC stands for Computer Numerical Control.

• It uses pre-programmed instructions to control the movement of the machine.

• CNC machines are widely used in manufacturing industries for tasks like cutting, drilling, milling, and turning.

• They offer high precision, repeatability, and automation.

• Examples of CNC machines include CNC mills, lathes, routers, and plasma cutters.

Injection moulding is a manufacturing process used to produce parts by injecting molten material into a mould.

• Injection moulding is a widely used method for manufacturing plastic parts.

• It involves injecting molten material, typically plastic, into a mould cavity.

• The molten material solidifies inside the mould, taking its shape.

• The mould is then opened, and the finished part is ejected.

• Injection moulding allows for high production volumes and complex part geometries.

• It is used...read more

Injection moulding is a manufacturing process used to produce parts by injecting molten material into a mould.

• The material is melted in the injection moulding machine and then injected into the mould

• The mould is cooled to solidify the material and then opened to release the finished product

• The process can be used to produce a wide range of products, from small parts to large automotive components

• Injection moulding is commonly used in industries such as automotive, medical, an...read more

Energy conservation is the practice of reducing energy consumption to save resources and reduce environmental impact.

• It involves using energy-efficient technologies and practices

• Examples include using LED light bulbs, turning off electronics when not in use, and using public transportation

• Energy conservation can also involve using renewable energy sources like solar or wind power

• It is important for reducing greenhouse gas emissions and combating climate change

Valve instrumentation and process control involves the use of instruments to monitor and control the flow, pressure, and temperature of fluids in industrial processes.

• Valve instrumentation refers to the use of instruments such as pressure gauges, flow meters, and temperature sensors to measure and monitor the conditions of fluids flowing through valves.

• Process control involves the use of control systems to regulate and manipulate the operation of valves and other equipment in...read more

KEI Industries produces a variety of cables including power cables, control cables, instrumentation cables, and specialty cables.

• Power cables

• Control cables

• Instrumentation cables

• Specialty cables

The maximum voltage of cables produced by KEI Industries is 1100V.

• KEI Industries produces cables with a maximum voltage of 1100V.

• The cables are designed to handle high voltage applications.

• These cables are commonly used in industrial and commercial settings.

• KEI Industries ensures quality and safety standards in their cable production.

A boiler is a closed vessel used to generate steam or hot water for heating purposes.

• Boilers are commonly used in industries such as power generation, chemical processing, and food and beverage production.

• They work by heating water or other fluids to produce steam, which is then used for various applications.

• Boilers can be fueled by a variety of sources, including natural gas, oil, coal, and biomass.

• They come in different types, such as fire-tube, water-tube, and electric boi...read more

Raw materials are the basic components used in production, while handling solvent involves safely managing chemicals.

• Raw materials are essential components used in manufacturing processes

• They can include items such as metals, plastics, chemicals, and more

• Handling solvents involves safely storing, using, and disposing of chemicals

• Proper ventilation, protective equipment, and training are important for solvent handling

• Examples of solvents include acetone, ethanol, and xylene