1000+ Production Engineer Interview Questions and Answers

Answers to questions related to Production Engineering

• Hydro grip is a type of tool holder that uses hydraulic pressure to clamp the tool

• Plate size of the machine depends on the specific machine being used

• Runout of tool can be controlled by using a precision collet or chuck, checking for wear and damage, and ensuring proper tool alignment

• Drawing knowledge is important for understanding technical specifications and tolerances

To manufacture a product with low loss and good quality, one must focus on optimizing the production process and ensuring quality control measures are in place.

• Conduct a thorough analysis of the production process to identify areas for improvement

• Implement lean manufacturing principles to reduce waste and increase efficiency

• Invest in quality control measures such as regular inspections and testing

• Train employees on proper manufacturing techniques and quality control procedure...read more

Explanation of how to calculate OEE, 7 QC tools, TPM, JH steps, SPC

• OEE = Availability x Performance x Quality

• 7 QC tools include Pareto chart, fishbone diagram, control chart, etc.

• TPM involves total employee involvement in maintenance

• JH steps include job analysis, job design, job instruction, etc.

• SPC involves statistical analysis of process data

A pictorial representation of a SI engine with valve opening, TDC, and BDC.

• SI engine stands for Spark Ignition engine, which is commonly used in gasoline-powered vehicles.

• Valve opening refers to the movement of the intake and exhaust valves to allow fuel-air mixture in and exhaust gases out of the combustion chamber.

• TDC (Top Dead Center) is the position of the piston at the extreme top of its stroke.

• BDC (Bottom Dead Center) is the position of the piston at the extreme bottom ...read more

The number of sizes used in production depends on the machine and the product being manufactured.

• The number of sizes used in production varies depending on the machine and product

• Different machines may require different sizes for production

• The number of sizes used can be determined by analyzing the production process and the machine specifications

Chemical processes involve the transformation of raw materials into useful products using chemical reactions.

• Examples of chemical processes include distillation, fermentation, and polymerization.

• Valves are commonly used in chemical processes to control the flow of fluids.

• pH is a measure of the acidity or basicity of a solution.

• Types of pumps used in chemical processes include centrifugal pumps, positive displacement pumps, and diaphragm pumps.

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

To solve problems in robots and detect faults, various techniques can be used such as monitoring sensors, analyzing error logs, conducting regular maintenance, and implementing diagnostic algorithms.

• Monitor sensors to detect any abnormal readings or malfunctions.

• Analyze error logs generated by the robot to identify recurring issues or patterns.

• Perform regular maintenance checks to ensure all components are functioning properly.

• Implement diagnostic algorithms that can analyze ...read more

Resistance and capacitance values can be calculated using various formulas and tools.

• Resistance can be calculated using Ohm's law: R = V/I

• Capacitance can be calculated using the formula: C = Q/V

• The values can also be determined using multimeters or online calculators

• The color code on resistors can be used to determine their resistance value

• The capacitance value can be determined by reading the markings on the capacitor

• The values can also be determined through experimentation ...read more

Productivity can be improved by optimizing processes, utilizing technology, and investing in employee training.

• Streamline processes to eliminate inefficiencies

• Implement technology to automate tasks and increase accuracy

• Provide training and development opportunities to enhance skills and knowledge

• Set clear goals and expectations for employees

• Encourage collaboration and communication among team members

SMED stands for Single-Minute Exchange of Die. It is a lean manufacturing technique used to reduce setup time in production processes.

• SMED aims to minimize the time required to change a machine or process from running one product to another.

• It involves separating internal and external setup tasks, converting internal tasks to external ones, and streamlining the overall process.

• By implementing SMED, companies can increase production flexibility, reduce downtime, and improve ov...read more

Kneader capacity refers to the maximum amount of material that can be processed in a kneader. It can be calculated based on the volume or weight of the material.

• Kneader capacity is typically measured in terms of volume or weight.

• To calculate the capacity based on volume, you need to know the dimensions of the kneader vessel and the fill level.

• For example, if the vessel has a diameter of 1 meter and a height of 2 meters, and the fill level is 80%, the capacity would be calcula...read more

The 7 tools in production are used for quality control and process improvement.

• Check sheets

• Control charts

• Histograms

• Pareto charts

• Scatter diagrams

• Flowcharts

• Cause-and-effect diagrams

G code is a programming language used in CNC machines to control their movements and operations.

• G code is a standardized language used in manufacturing to control CNC machines.

• It consists of a series of commands that tell the machine what to do, such as move the tool to a specific location or change the speed of the spindle.

• G code is used to create complex parts with high precision and accuracy.

• Examples of G code commands include G00 (rapid positioning), G01 (linear interpola...read more

To control wastage and increase productivity, proper planning, training, and monitoring are necessary.

• Implement lean manufacturing techniques

• Train employees on efficient use of resources

• Monitor production processes to identify areas of improvement

• Implement quality control measures to reduce defects

• Optimize production schedules to reduce downtime

• Invest in automation to reduce manual labor

• Encourage employee feedback and suggestions for improvement

Minimize labour and product cost without compromising quantity.

• Automate processes to reduce labour cost

• Optimize supply chain to reduce product cost

• Implement lean manufacturing principles

• Negotiate better deals with suppliers

• Reduce waste and improve efficiency

• Invest in technology to improve productivity

• Train employees to improve skills and reduce errors

Answering questions related to starting pump, two phase flow, control station work, ejector problem and troubleshooting, and vacuum in column.

• To start a pump, ensure that the suction line is filled with liquid and open the discharge valve. Then, turn on the motor and gradually open the suction valve.

• Two phase flow is when both liquid and gas are present in the pipe. This can cause issues with pump performance and require special considerations in design.

• Control stations are u...read more

Yes, a bore gauge is a measuring tool used to measure the diameter of holes. To set it, the gauge is adjusted to match the desired diameter.

• A bore gauge is used to measure the diameter of holes

• To set the bore gauge, it is adjusted to match the desired diameter

• The gauge is then inserted into the hole and the measurement is taken

• Bore gauges come in various types such as dial bore gauges, digital bore gauges, and telescoping bore gauges

Sorry, I cannot answer this question as it lacks context and information.

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

Two-stroke and four-stroke engines differ in their operation and design.

• Two-stroke engines complete a power cycle in two strokes of the piston, while four-stroke engines complete it in four strokes.

• Two-stroke engines have a simpler design with fewer moving parts, making them lighter and more compact.

• Four-stroke engines are more fuel-efficient and produce less pollution due to separate intake, compression, power, and exhaust strokes.

• Two-stroke engines require a mixture of fuel...read more

The 7 wastes of production are categories of waste that can occur in manufacturing processes.

• Transportation: Unnecessary movement of materials or products

• Inventory: Excess inventory leading to storage costs and potential waste

• Motion: Unnecessary movement of workers

• Waiting: Idle time during production processes

• Overproduction: Producing more than needed

• Overprocessing: Using more resources than necessary

• Defects: Errors leading to rework or scrap

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 material used for relay contact soldering is typically silver or silver alloy.

• Silver or silver alloy is commonly used for relay contact soldering due to its high electrical conductivity and low resistance.

• Silver solder has a lower melting point compared to other solder materials, making it suitable for delicate electronic components.

• The use of silver or silver alloy solder helps ensure reliable and efficient electrical connections in relay contacts.

• Other materials such as...read more

LEL and UEL are Lower Explosive Limit and Upper Explosive Limit respectively. They define the range of flammable gas concentration.

• LEL is the minimum concentration of gas in air that can ignite and cause an explosion.

• UEL is the maximum concentration of gas in air that can ignite and cause an explosion.

• The range between LEL and UEL is known as the explosive range.

• Maintaining gas concentration within safe limits is crucial to prevent explosions.

• For example, the LEL of methane i...read more

Autoclave is a device used for sterilization by subjecting objects to high-pressure steam.

• Autoclaves are commonly used in medical and laboratory settings.

• They work by using high-pressure steam to kill bacteria, viruses, and other microorganisms.

• Autoclaves can sterilize a variety of materials, including surgical instruments, glassware, and textiles.

• The sterilization process typically takes around 15-20 minutes.

• Autoclaves have safety features to prevent explosions or other acci...read more

DFT in painting stands for Dry Film Thickness.

• DFT is the thickness of the paint film after it has dried.

• It is measured using a coating thickness gauge.

• The DFT is important for ensuring proper protection and appearance of the painted surface.

• For example, a coating may require a minimum DFT of 2 mils to provide adequate corrosion protection.

• DFT can also affect the drying time and curing of the paint.

Parameters like mold temperature, pouring temperature, and cooling rate can reduce the casting cycle time without affecting quality.

• Mold temperature

• Pouring temperature

• Cooling rate

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

HITACHI ASTEMO CHENNAI PVT LTD is involved in manufacturing various products and providing engineering solutions.

• HITACHI ASTEMO CHENNAI PVT LTD manufactures a wide range of products such as industrial machinery, automotive components, and electronic devices.

• They provide engineering solutions for various industries including manufacturing, automotive, and electronics.

• The company focuses on innovation, quality, and customer satisfaction in their production processes.

• They have a...read more

The minimum value measured by a height gauge is the smallest distance that can be accurately measured by the instrument.

• The minimum value is determined by the resolution of the gauge

• For example, a gauge with a resolution of 0.01mm can measure a minimum value of 0.01mm

• The minimum value can also be affected by the accuracy of the gauge

• It is important to calibrate the gauge regularly to ensure accurate measurements

The list count of vernier caliper is 20.

• Vernier caliper has two scales - main scale and vernier scale.

• The main scale has 10 divisions, each division is 1 mm.

• The vernier scale has 9 divisions, each division is 0.9 mm.

• The list count is the number of smallest divisions on the vernier scale that coincide with a division on the main scale.

• In case of vernier caliper, the list count is 20.

Idle time refers to the period when a machine or worker is not engaged in any productive activity.

• Idle time can occur due to various reasons such as equipment breakdowns, waiting for materials, or lack of work orders.

• To reduce idle time, proactive maintenance and regular equipment inspections can help prevent breakdowns.

• Efficient scheduling and coordination of tasks can minimize waiting time for materials or resources.

• Implementing lean manufacturing principles like just-in-ti...read more

M-codes are machine codes used to control CNC machines. M00 is program stop, M30 is program end, M08 is coolant on, and M01 is optional stop.

• M-codes are used to control CNC machines

• M00 is used to stop the program

• M30 is used to end the program

• M08 is used to turn on the coolant

• M01 is used to create an optional stop

Run time refers to the time it takes for a program or process to execute. It can be improved by optimizing algorithms, using efficient data structures, and parallelizing tasks.

• Run time is the duration it takes for a program or process to complete its execution.

• To improve run time, one can optimize algorithms by reducing unnecessary computations or using more efficient algorithms.

• Using efficient data structures like hash tables or binary trees can also improve run time by redu...read more

Take time, cycle time, and lead time are important metrics in production engineering.

• Take time is the time required to complete a single unit of production.

• Cycle time is the time required to complete a single step in the production process.

• Lead time is the time required to complete an entire production process from start to finish.

• Reducing cycle time can increase production efficiency.

• Reducing lead time can improve customer satisfaction.

• Take time is often used to calculate cy...read more

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

Explanation of how to calculate OEE, use 7QC tools, TMP, productivity, team building, manpower management, SAP module, inventory control, and scrap reduction.

• OEE calculation involves multiplying availability, performance, and quality percentages

• 7QC tools include Pareto chart, fishbone diagram, control chart, etc.

• TMP stands for Total Maintenance Productivity and measures maintenance efficiency

• Productivity can be calculated by dividing output by input

• Team building involves acti...read more

To improve Lean Manufacturing and increase production, educate and skill manpower, line balancing, cycle time, and effective manpower handling are crucial.

• Implementing a continuous improvement process to identify and eliminate waste

• Standardizing work processes to reduce variability and increase efficiency

• Training and cross-training employees to improve their skills and flexibility

• Using technology and automation to streamline processes and reduce manual labor

• Optimizing line ba...read more

Composite materials are made by combining two or more different materials to create a new material with improved properties.

• Composite materials are used in various industries such as aerospace, automotive, construction, and sports.

• They are made by combining a matrix material (such as resin) with reinforcement materials (such as fibers or particles).

• The matrix material holds the reinforcement materials together and transfers loads between them.

• Common types of composites includ...read more

Production is the process of creating goods and services using various resources and techniques.

• Production involves the use of resources such as labor, machinery, and raw materials to create goods and services.

• Key performance indicators (KPIs) for production may include metrics such as production output, efficiency, and quality.

• IATF stands for International Automotive Task Force, which is a group of automotive manufacturers and their respective trade associations that develop...read more

The best orientation for metal 3D printing depends on the geometry of the part and the desired mechanical properties. Metals that can be printed in laser machines include stainless steel, titanium, aluminum, and cobalt-chrome.

• The orientation should minimize the need for support structures

• The orientation should maximize the strength of the part in the desired direction

• Stress analysis can help determine the optimal orientation

• Stainless steel, titanium, aluminum, and cobalt-chro...read more

Control plan is a document that outlines the steps to be taken to ensure quality control in a manufacturing process.

• It is a written document that outlines the steps to be taken to ensure quality control in a manufacturing process

• It includes details on the process, the measurements to be taken, and the frequency of those measurements

• It is used to ensure that the manufacturing process is consistent and that the final product meets the required quality standards

• It is often used ...read more

Various types of equipment are used in production engineering.

• Machining equipment such as lathes, milling machines, and drill presses

• Welding equipment including MIG, TIG, and stick welders

• Cutting equipment such as plasma cutters and waterjets

• Material handling equipment like cranes and forklifts

• Testing equipment such as gauges, micrometers, and CMMs

M code is a programming language used in CNC machines to control various functions such as spindle speed, tool changes, and coolant.

• M codes are used to initiate specific actions or functions on a CNC machine.

• M codes are typically followed by a numerical value that specifies the desired action.

• Examples of M codes include M03 for spindle on clockwise, M05 for spindle stop, and M08 for coolant on.

• M codes can be customized and programmed to meet specific production needs.

• M codes ...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

Tools that can be used in the given drawing for Production Engineer.

• CAD software like AutoCAD, SolidWorks, etc. for designing and drafting

• CAM software like Mastercam, EdgeCAM, etc. for creating toolpaths and generating G-code

• CNC machines for cutting, drilling, and shaping the parts

• Measuring tools like calipers, micrometers, etc. for quality control

• Hand tools like wrenches, pliers, etc. for assembly and maintenance