1000+ Production Engineer Interview Questions and Answers

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

Electric motors convert electrical energy into mechanical energy, while electric generators convert mechanical energy into electrical energy.

• Electric motors use electrical energy to create motion, while electric generators use motion to create electrical energy.

• Electric motors have a rotor that spins inside a stator, while electric generators have a rotor that is turned by an external force to produce electricity.

• Examples of electric motors include those used in household app...read more

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

The question is unclear and does not make sense in the context of CNC machines.

• The term 'infader' is not a commonly used term in the CNC industry.

• It is possible that the interviewer meant to ask about 'infeed' or 'feed rate' instead.

• The number of infeeds or feed rates in a CNC machine can vary depending on the specific machine and its programming.

• It is important to clarify any unclear questions in an interview to ensure accurate answers.

Kaizen is a Japanese term meaning continuous improvement. There are several types of Kaizen, including Gemba Kaizen, Flow Kaizen, and Process Kaizen.

• Kaizen is a Japanese business philosophy focused on continuous improvement.

• Gemba Kaizen involves making improvements at the workplace where the work is done.

• Flow Kaizen focuses on improving the flow of work or processes.

• Process Kaizen involves making improvements to specific processes within an organization.

When a freon compressor gets tripped, it can lead to a loss of cooling capacity and potential damage to the system.

• Check for any fault codes or alarms on the compressor control panel.

• Inspect the compressor for any visible signs of damage or overheating.

• Reset the compressor and monitor its operation to ensure it is functioning properly.

• Investigate the root cause of the trip to prevent future occurrences.

• Consider contacting a qualified technician for further assistance if neede...read more

Reduced flow of cooling water in furnace can lead to overheating, potential damage to equipment, and decreased efficiency.

• Overheating of furnace components

• Potential damage to furnace equipment

• Decreased efficiency in cooling process

Excess DFT can lead to increased cost and longer production time.

• Excess DFT can lead to increased material usage and waste.

• It can also lead to longer production time and increased cost.

• The excess DFT may also affect the performance and durability of the product.

• It is important to ensure that the DFT is within the specified range to avoid these issues.

Implemented kaizen activities to improve production efficiency and reduce waste.

• Introduced visual management system to track production progress

• Reduced setup time by implementing SMED techniques

• Implemented 5S methodology to improve workplace organization

• Conducted regular Gemba walks to identify areas for improvement

• Implemented Poka-yoke techniques to prevent defects

• Trained employees on problem-solving techniques to encourage continuous improvement

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

Loading a die on a press machine requires proper alignment and securing of the die.

• Ensure the press machine is turned off and the die is clean and free of debris.

• Align the die with the press machine's ram and bolster.

• Secure the die with clamps or bolts.

• Adjust the press machine's stroke and pressure settings as needed.

• Test the die with a few trial runs before starting production.

• Regularly inspect and maintain the die and press machine for optimal performance.

Welding electrodes and filler wires are used in welding processes to join two metals together.

• Types of welding electrodes include coated electrodes, non-coated electrodes, and tungsten electrodes.

• Filler wires are classified based on the type of metal being welded, such as aluminum, stainless steel, and nickel alloys.

• Coated electrodes have a flux coating that protects the weld from contamination and provides a shielding gas.

• Tungsten electrodes are used in TIG welding and are m...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

I have experience working with various types of machines including CNC machines, lathes, milling machines, and grinders.

• CNC machines

• Lathes

• Milling machines

• Grinders

Lean manufacturing is a systematic approach to identifying and eliminating waste in the production process.

• Focuses on continuous improvement and waste reduction

• Involves all employees in the process

• Uses tools such as value stream mapping and 5S

• Examples include Toyota Production System and Kaizen

Calculating OEE, PPM, 7QC tool SPC, Injection Molding Defects, Tubrolsutting, and Red Bin Analysis in Production Engineering

• OEE can be calculated by multiplying Availability, Performance, and Quality

• PPM (Parts Per Million) is a measure of defects per million parts produced

• 7QC (Seven Quality Control) tools include Pareto charts, cause-and-effect diagrams, and control charts

• SPC (Statistical Process Control) involves monitoring and controlling a process to ensure it stays within...read more

Safety measures during installation and commissioning on site

• Ensure all personnel involved are trained and equipped with appropriate PPE

• Conduct a thorough risk assessment and implement control measures

• Ensure all equipment is properly grounded and isolated

• Follow all relevant safety regulations and standards

• Have a first aid kit and emergency response plan in place

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

Yes, I have experience in designing and analyzing steel structures.

• I have worked on various projects involving steel structures such as bridges, buildings, and industrial facilities.

• I am familiar with industry standards and codes such as AISC, ASCE, and ACI.

• I have experience in using software such as STAAD.Pro and SAP2000 for structural analysis and design.

• I have also conducted site inspections and provided recommendations for repairs and maintenance of steel structures.

• Overa...read more

Production is the process of creating goods or services, while manufacturing is a subset of production that involves the creation of physical goods.

• Production involves both goods and services, while manufacturing is limited to physical goods.

• Production is a broader term that includes manufacturing, while manufacturing is a subset of production.

• Manufacturing involves the use of machinery and tools to create physical goods, while production can involve a variety of processes.

• Ex...read more

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.

Hydraulic machines use fluid power to generate, control, and transmit energy.

• Hydraulic machines work by using a liquid, typically oil, to transmit force and motion.

• They operate based on Pascal's law, which states that pressure applied to a confined fluid is transmitted undiminished in every direction.

• Hydraulic machines work on the principle of converting mechanical energy into hydraulic energy and vice versa.

• Examples of hydraulic machines include hydraulic presses, hydraulic ...read more

Common tools for measuring on a CNC machine include calipers, micrometers, height gauges, and dial indicators.

• Calipers are used for measuring distances between two points on a workpiece.

• Micrometers are used for precise measurements of small distances or thicknesses.

• Height gauges are used for measuring the vertical distance from a reference point to a workpiece.

• Dial indicators are used for measuring small distances or variations in position.

• Other tools may include depth gauges...read more

RC certification includes various clauses and codes to ensure compliance and safety in production processes.

• RC certification typically includes around 10 clauses that cover various aspects of production.

• Examples of clauses include: Management Responsibility, Resource Management, and Product Realization.

• Each clause may have specific codes that detail requirements for compliance.

• For instance, the Management Responsibility clause may include codes related to leadership and commi...read more

An RC certificate verifies compliance with safety standards, while an RC logo indicates certification status visually.

• RC stands for 'Registration Certificate', which is issued to confirm that a product meets specific regulatory standards.

• An RC certificate is a formal document, while an RC logo is a visual representation of that certification.

• For example, an RC certificate for a toy ensures it is safe for children, while the RC logo on the packaging indicates this certificatio...read more

LEL of ethanol is 3.3% by volume; controlling measures include ventilation, monitoring, and proper storage.

• LEL of ethanol is 3.3% by volume in air.

• Proper ventilation is essential to dilute flammable vapors.

• Use of gas detectors to monitor ethanol concentration.

• Implementing explosion-proof equipment in production areas.

• Regular training for employees on handling flammable materials.

Implemented kaizen initiatives to streamline processes, reduce waste, and enhance efficiency in production workflows.

• Conducted time-motion studies to identify bottlenecks in the assembly line, leading to a 15% reduction in cycle time.

• Introduced standardized work procedures that minimized variability and improved training efficiency for new employees.

• Implemented a visual management system using Kanban boards to track workflow and reduce waiting times between processes.

• Facilita...read more

In a pressurized situation, time management and production can be managed by prioritizing tasks, delegating responsibilities, and maintaining clear communication.

• Identify critical tasks and prioritize them based on their importance and urgency

• Delegate responsibilities to team members based on their strengths and expertise

• Maintain clear communication with team members to ensure everyone is aware of their responsibilities and deadlines

• Regularly review progress and adjust plans ...read more

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

Yes, as a Production Engineer, I handle all aspects of manpower, material planning, design, and EHS.

• I am responsible for managing the manpower requirements for production processes.

• I oversee the planning and procurement of materials needed for production.

• I am involved in the design and improvement of production systems and processes.

• I ensure compliance with environmental, health, and safety regulations.

• Examples: Developing production schedules, coordinating with suppliers, im...read more

To handle production and manpower, it is important to optimize processes, allocate resources effectively, and prioritize tasks.

• Analyze production requirements and create a production plan

• Optimize production processes to increase efficiency

• Allocate manpower based on workload and skillset

• Implement effective communication channels to coordinate tasks

• Monitor production progress and make adjustments as needed

• Prioritize tasks based on urgency and impact on production

• Provide trainin...read more

Product inspection involves thorough examination of the product to ensure it meets quality standards.

• Identify the specific quality standards for the product

• Inspect the product visually for defects or irregularities

• Use measuring tools to check dimensions and tolerances

• Perform functional tests to ensure the product works as intended

• Document any issues found and report to appropriate personnel

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

Furnace brazing is a joining process in which two or more metal items are joined together using a filler metal that has a lower melting point than the base metals.

• Furnace brazing involves heating the metal parts in a furnace to a temperature above the melting point of the filler metal but below the melting point of the base metals.

• The filler metal is then drawn into the joint by capillary action, creating a strong bond between the metal parts.

• My current role in my company inv...read more

Red bin activity, 5S, 7 Waste, and problem-solving techniques are important concepts in lean manufacturing for improving efficiency and reducing waste.

• Red bin activity involves using red bins to highlight areas of waste or inefficiency in the production process.

• 5S is a methodology for organizing the workplace to improve efficiency and effectiveness (Sort, Set in order, Shine, Standardize, Sustain).

• 7 Waste refers to the seven types of waste in manufacturing: overproduction, wa...read more

OEE stands for Overall Equipment Efficiency, a measure of how well a manufacturing process is performing.

• OEE is calculated by multiplying Availability, Performance, and Quality percentages.

• Availability = (Operating Time / Planned Production Time) * 100

• Performance = (Ideal Cycle Time / Total Cycle Time) * 100

• Quality = (Good Count / Total Count) * 100

• OEE = Availability% x Performance% x Quality%

Testing procedures for MDF products according to BIS standards

• Testing for physical properties like density, moisture content, and thickness

• Testing for mechanical properties like modulus of rupture and internal bond strength

• Testing for formaldehyde emission levels to ensure compliance with BIS standards

• Testing for dimensional stability and surface soundness

• Examples of tests include BIS 1734, BIS 3087, and BIS 12406

Yes, I am able to handle work load and pressure effectively in the working area.

• I have experience managing multiple projects simultaneously

• I prioritize tasks based on deadlines and importance

• I communicate effectively with team members to delegate tasks and ensure smooth workflow

Production planning involves creating a detailed plan for manufacturing products efficiently. 5S and Kaizen are methodologies used to improve productivity and efficiency in production.

• Production planning involves setting goals, determining resources needed, creating schedules, and monitoring progress.

• 5S is a methodology focused on organizing the workplace to improve efficiency and eliminate waste. It stands for Sort, Set in order, Shine, Standardize, and Sustain.

• Kaizen is a J...read more

Hydraulic systems use fluids to transmit power and operate machinery.

• Hydraulic systems use incompressible fluids, typically oil or water, to transmit power.

• The principle of hydraulic is based on Pascal's law, which states that pressure applied to a fluid in a closed system is transmitted equally to all parts of the system.

• Hydraulic systems are used in a variety of applications, such as heavy machinery, automotive brakes, and aircraft landing gear.

• Hydraulic systems can provide...read more

Our company handles a variety of chemicals and solvents depending on the production requirements.

• We handle chemicals and solvents based on the production needs

• The types and quantities of chemicals and solvents vary

• We follow strict safety protocols for handling and storage

• Examples include acetone, ethanol, hydrochloric acid, and sodium hydroxide

Maintain production quantity and quality output by optimizing processes, training employees, and monitoring performance.

• Regularly review and optimize production processes to eliminate inefficiencies and reduce waste.

• Provide ongoing training and development opportunities for employees to improve their skills and knowledge.

• Implement quality control measures to ensure that products meet or exceed customer expectations.

• Monitor performance metrics regularly to identify areas for i...read more

NPI involves several steps including design, testing, validation, and production.

• Designing the product and creating a prototype

• Testing the prototype to ensure it meets specifications

• Validating the product through various tests and certifications

• Preparing for production by creating a manufacturing plan and sourcing materials

• Producing the product and conducting quality control checks

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

Heat transfer types include conduction, convection, and radiation. Kettle type reboiler is a type of heat exchanger used in distillation processes. ISO systems are international standards for quality management.

• Conduction transfers heat through a material without any movement of the material itself

• Convection transfers heat through the movement of fluids or gases

• Radiation transfers heat through electromagnetic waves

• Kettle type reboilers are used in distillation processes to va...read more