1000+ Production Engineer Interview Questions and Answers

Lean manufacturing focuses on minimizing waste and maximizing value, while traditional manufacturing focuses on maximizing output.

• Lean manufacturing aims to reduce waste in all forms, including time, materials, and effort.

• Traditional manufacturing focuses on maximizing output and efficiency, often at the expense of waste.

• Lean manufacturing involves continuous improvement and a focus on customer value.

• Traditional manufacturing may prioritize production speed over customer need...read more

TPM stands for Total Productive Maintenance and JH stands for Job Hazard Analysis. JH 7 steps are the steps involved in conducting a JH analysis.

• TPM is a maintenance strategy aimed at maximizing the productivity of equipment and minimizing downtime.

• JH is a safety analysis technique used to identify potential hazards in a job or task.

• JH 7 steps involve breaking down a job into steps, identifying potential hazards, determining preventive measures, and implementing them.

• Example ...read more

Hazards in the plant and their control

• Chemical hazards: Proper storage and handling of hazardous chemicals

• Electrical hazards: Regular inspection and maintenance of electrical equipment

• Mechanical hazards: Implementation of safety guards and procedures

• Fire hazards: Installation of fire detection and suppression systems

• Ergonomic hazards: Providing ergonomic workstations and equipment

• Noise hazards: Use of hearing protection and noise control measures

Cycle time, Takt time, SBP, Indent, 7QC tools are important concepts in production engineering.

• Cycle time is the time taken to complete one cycle of an operation.

• Takt time is the time taken to produce one unit of a product to meet customer demand.

• SBP stands for Standardized work, Built-in quality, and Process improvement.

• Indent is a document used to order materials or services from suppliers.

• 7QC tools are a set of quality control tools used to identify and solve production pr...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

The perfect roll diameter for a 5.5 mm wire rod coil depends on factors like material properties and coil weight.

• Consider the material properties of the wire rod, such as tensile strength and elasticity

• Calculate the coil weight to determine the required roll diameter

• Consult industry standards and guidelines for recommended roll diameters

• Perform testing and adjustments to optimize the roll diameter for production efficiency

Production efficiency is calculated by dividing the actual output by the standard output and multiplying by 100.

• Calculate the actual output of the production process.

• Determine the standard output, which is the expected or target output.

• Divide the actual output by the standard output.

• Multiply the result by 100 to get the production efficiency percentage.

Batch production involves producing a specific quantity of items at a time, while mass production involves continuous production of large quantities.

• Batch production is more flexible and allows for customization of products.

• Mass production is more efficient and cost-effective for producing large quantities.

• Batch production is common in industries like pharmaceuticals, bakeries, and breweries.

• Mass production is common in industries like automotive, electronics, and consumer go...read more

I had 8 subjects in my btech college.

• I had subjects like Mechanical Engineering, Electrical Engineering, Computer Science, etc.

• Each semester had different subjects based on the curriculum.

• Some common subjects included Thermodynamics, Control Systems, Data Structures, etc.

Reading a drawing requires understanding of symbols, dimensions, and scale.

• Identify the title block for important information

• Understand the scale and units of measurement

• Read the dimensions and tolerances

• Identify symbols and annotations

• Understand the drawing's purpose and context

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

OEE, SPC, 8D, KIEZEN, COST SAVING are important concepts in production engineering.

• OEE (Overall Equipment Effectiveness) measures the efficiency of production equipment.

• SPC (Statistical Process Control) is a method of monitoring and controlling a production process.

• 8D (Eight Disciplines) is a problem-solving methodology used to identify, correct, and prevent recurring problems.

• KIEZEN is a Dutch acronym for a problem-solving methodology that stands for: Define, Measure, Analyz...read more

The procedure for opening and maintaining a hammer involves several steps to ensure proper functionality and safety.

• Inspect the hammer for any damage or wear before each use

• Clean the hammer regularly to remove debris and prevent rust

• Check and tighten any loose screws or parts as needed

• Store the hammer in a dry place to prevent corrosion

• Replace the handle if it becomes loose or damaged

Issues with short quantity production include higher costs, longer lead times, and difficulty in meeting demand.

• Higher costs due to lack of economies of scale

• Longer lead times as production processes are not optimized for small batches

• Difficulty in meeting demand as production capacity may not be sufficient

Optimizing methane gas production involves efficient feedstock selection, process optimization, and waste management.

• Selecting the right feedstock with high methane content

• Optimizing the process parameters such as temperature, pressure, and pH

• Implementing waste management techniques to reduce the buildup of inhibitory compounds

• Using advanced technologies such as anaerobic digestion and membrane separation

• Regular maintenance and monitoring of the production system

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

The least value of micrometre is 0.01 mm and the least count of vernier caliper is 0.02 mm.

• The least value of a micrometre is typically 0.01 mm.

• The least count of a vernier caliper is usually 0.02 mm.

• These values represent the smallest measurements that can be accurately read using these tools.

An injection molding machine is a manufacturing machine used to produce parts by injecting molten material into a mold.

• Injection molding machines are commonly used in manufacturing industries to produce plastic parts.

• The machine consists of a hopper, a barrel, an injection unit, a clamping unit, and a mold.

• The molten material is injected into the mold under high pressure, where it cools and solidifies to form the desired part.

• Injection molding machines can be used to produce ...read more

The clearance between punch pin and material depends on the material type, thickness, and punch diameter.

• Clearance is the gap between the punch pin and the material being punched.

• It is important to have the correct clearance to avoid damage to the punch and material.

• Clearance can vary depending on the material type, thickness, and punch diameter.

• A general rule of thumb is to have a clearance of 10-20% of the material thickness.

• For example, if the material thickness is 1mm, th...read more

There are two main types of engines: internal combustion engines and external combustion engines. Parameters to check include fuel efficiency, emissions, power output, and overall performance.

• Internal combustion engines: gasoline engines, diesel engines

• External combustion engines: steam engines

• Parameters to check: fuel efficiency, emissions, power output, performance

The number of Engineering Documents processed in an EPC project varies depending on the size and complexity of the project.

• The number of Engineering Documents processed in an EPC project can range from hundreds to thousands.

• These documents include drawings, specifications, calculations, reports, and other technical documents.

• The exact number of documents will depend on the scope of the project, the number of disciplines involved, and the project timeline.

• For example, a small ...read more

7QC tools check sheet is a document used to collect and analyze data, while Pareto diagram is a graphical representation of the data.

• 7QC tools check sheet is used to identify and solve problems in production processes

• It helps in collecting and analyzing data related to the process

• Pareto diagram is a bar graph that shows the relative frequency or size of problems in descending order of importance

• It helps in identifying the most significant problems that need to be addressed fi...read more

Overall Equipment Effectiveness (OEE) is a measure of how effectively equipment is being utilized to produce quality products.

• OEE is calculated by multiplying availability, performance, and quality rates.

• Availability rate measures the percentage of time the equipment is available for production.

• Performance rate measures the speed at which the equipment is producing products compared to its maximum capacity.

• Quality rate measures the percentage of products that meet the require...read more

Rejection handling is the process of identifying and addressing rejected products. Red bin analysis is a method of analyzing rejected products to determine the cause of rejection.

• Rejection handling involves identifying and segregating rejected products

• Red bin analysis involves analyzing rejected products to determine the root cause of rejection

• The data collected during red bin analysis can be used to improve production processes and reduce rejection rates

• Common causes of reje...read more

Torque is a twisting force that causes rotation, while force is a push or pull that causes an object to move or change direction.

• Torque is measured in units of force multiplied by distance, such as newton-meters or pound-feet.

• Force is measured in units of mass multiplied by acceleration, such as newtons or pounds.

• Torque is important in rotating machinery, such as engines and motors.

• Force is important in many applications, such as lifting heavy objects or pushing a car.

• Both to...read more

Injection moulding machine is located in the production area and problem solving involves identifying and resolving issues with the machine and the moulds.

• Injection moulding machine is typically located in the production area

• Problem solving involves identifying and resolving issues with the machine and the moulds

• Common problems include issues with the temperature, pressure, and material flow

• Solutions may involve adjusting settings, replacing parts, or modifying the mould desi...read more

BS6 emissions standards are more stringent than BS4, with lower limits on emissions of pollutants like nitrogen oxides and particulate matter.

• BS6 standards have stricter limits on emissions of pollutants like nitrogen oxides (NOx) and particulate matter (PM) compared to BS4.

• BS6 compliant vehicles are required to have advanced emission control technologies like selective catalytic reduction (SCR) and diesel particulate filters (DPF).

• BS6 standards aim to reduce harmful emission...read more

G76 and G92 are both G-codes used in CNC machining, but they have different functions.

• G76 is used for thread cutting, while G92 is used for setting the work offset.

• G76 specifies the thread pitch, depth, and other parameters, while G92 sets the position of the workpiece in relation to the tool.

• G76 is used with a threading tool, while G92 is used with a work offset probe or sensor.

• G76 is used to create external or internal threads, while G92 is used to set the workpiece origin ...read more

CNMG120408 is an indexable insert used in metal cutting operations.

• CNMG: ISO code for diamond-shaped inserts with 80-degree corners

• 12: Insert thickness in millimeters

• 04: Corner radius in millimeters

• 08: Insert length in millimeters

Grinding is a material removal process using an abrasive wheel, while turning is a machining process using a cutting tool to remove material from a rotating workpiece.

• Grinding is typically used for finishing operations, while turning is used for roughing and finishing

• Grinding produces a smoother surface finish than turning

• Turning is typically faster than grinding

• Grinding is used for materials that are too hard for turning, such as ceramics and carbides

• Turning is used for mate...read more

Managing people for good output requires effective communication, clear expectations, and recognition of achievements.

• Establish clear goals and expectations

• Provide regular feedback and constructive criticism

• Encourage open communication and collaboration

• Recognize and reward achievements

• Provide opportunities for growth and development

• Lead by example and maintain a positive attitude

The rejection control of the moulding machine is typically located on the control panel.

• The rejection control is usually a button or switch on the control panel.

• It may be labeled as 'reject' or 'scrap'.

• The control allows the operator to manually reject any defective parts produced by the machine.

• Some machines may also have an automatic rejection system that is programmed to detect and remove defective parts.

• The location of the rejection control may vary depending on the speci...read more

There are several types of heat exchangers used in manufacturing processes.

• Shell and tube heat exchanger

• Plate heat exchanger

• Double pipe heat exchanger

• Finned tube heat exchanger

• Air-cooled heat exchanger

Gemba is a Japanese term for 'the real place', power press is a machine used for stamping metal, tools used in power press include dies and punches, stamping process involves shaping metal by pressing it between dies.

• Gemba is a Japanese term meaning 'the real place' or 'the actual place where work is done'

• Power press is a machine used in metalworking to shape or cut metal using dies and punches

• Tools used in power press include dies (for shaping) and punches (for cutting)

• Stamp...read more

A transformer works by transferring electrical energy between two or more circuits through electromagnetic induction.

• Transformers consist of two coils of wire, known as the primary and secondary coils, wrapped around a core made of iron or other magnetic materials.

• When an alternating current flows through the primary coil, it creates a changing magnetic field which induces a voltage in the secondary coil.

• The ratio of the number of turns in the primary coil to the number of tu...read more

There are two main types of engines in automobiles: internal combustion engines and electric motors.

• Internal combustion engines: gasoline, diesel, rotary

• Electric motors: battery electric, hybrid electric

• Other types: steam engines (rarely used in modern automobiles)

When a machine stops working, immediate actions should be taken to diagnose and fix the issue to minimize downtime.

• Check for any error messages or indicators on the machine

• Inspect the machine for any visible damage or loose connections

• Refer to the machine's manual for troubleshooting steps

• Contact the maintenance team or a technician for assistance if needed

• Implement a backup plan to ensure production is not significantly impacted

Line balancing is the process of optimizing workloads across a production line. Loss cycle time refers to the time lost due to inefficiencies in the production process.

• Line balancing involves analyzing the production process to ensure that each workstation is being utilized efficiently

• The goal of line balancing is to minimize idle time and maximize productivity

• Loss cycle time refers to the time lost due to factors such as machine breakdowns, material shortages, and worker ine...read more

Karl Benz is credited as the first inventor of the automobile.

• Karl Benz, a German engineer, is widely regarded as the inventor of the automobile.

• He patented the first gasoline-powered car in 1886, known as the Benz Patent-Motorwagen.

• Benz's invention revolutionized transportation and paved the way for the modern automobile industry.

Yes, I can serve Utkarsh Company by utilizing my expertise in production engineering to enhance efficiency and quality in the pipe & fitting industry.

• Implementing lean manufacturing principles to streamline production processes

• Utilizing advanced technologies such as automation and robotics for increased productivity

• Developing and implementing quality control measures to ensure product reliability

• Collaborating with suppliers and vendors to optimize supply chain management

• Conti...read more

The source name of the laser cutting machine is typically the manufacturer's name or a specific model name.

• The source name could be the manufacturer's name, such as Trumpf or Amada.

• It could also be a specific model name, like Trumpf TruLaser Series or Amada LC3015.

First angle projection and third angle projection are two different methods used in mechanical drawings to represent a 3D object on a 2D plane.

• First angle projection is commonly used in Europe and Asia, while third angle projection is commonly used in North America.

• In first angle projection, the object is placed in the first quadrant and the views are projected onto the planes surrounding the object.

• In third angle projection, the object is placed in the third quadrant and the...read more

Production planning and control is the process of managing and optimizing the production process.

• Production planning involves creating a plan for the production process, including scheduling and resource allocation.

• Production control involves monitoring and adjusting the production process to ensure it stays on track with the plan.

• OEE (Overall Equipment Effectiveness) is a metric used to measure the efficiency of a production process.

• Cycle time is the time it takes to complet...read more

Density of Cu, Al, Mild steel, Stainless steel

• Density of Copper (Cu) is approximately 8.96 g/cm^3

• Density of Aluminum (Al) is approximately 2.70 g/cm^3

• Density of Mild Steel is approximately 7.85 g/cm^3

• Density of Stainless Steel can vary depending on the grade, but is typically around 7.9 g/cm^3

OEE stands for Overall Equipment Effectiveness and is a measure of how well a manufacturing process is performing.

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

• Availability is the ratio of operating time to planned production time.

• Performance is the ratio of actual production to maximum possible production.

• Quality is the ratio of good parts to total parts produced.

• OEE = Availability x Performance x Quality

• For example, if a machine operates for 8 hour...read more

A saccharification reactor is used in the production of biofuels and converts starch into sugars.

• It is a vessel where starch is mixed with enzymes to break down the starch into simple sugars.

• The simple sugars are then fermented to produce ethanol or other biofuels.

• The reactor is typically operated at high temperatures and pressures to optimize the saccharification process.

• Examples of enzymes used in the process include alpha-amylase and glucoamylase.

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.