1000+ Production Engineer Interview Questions and Answers

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.

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

Types of joints and welding symbols are essential in production engineering.

• Types of joints include butt joint, lap joint, corner joint, and T-joint.

• Welding symbols are used to communicate the details of the weld joint to be made, such as groove weld, fillet weld, plug weld, etc.

• Common welding symbols include square groove, V-groove, bevel groove, and J-groove.

• Welding symbols also indicate the welding process to be used, such as shielded metal arc welding (SMAW), gas tungsten...read more

4M refers to the key factors of production - Man, Machine, Material, and Method.

• Man: Refers to the human resources involved in production.

• Machine: Refers to the equipment and tools used in the production process.

• Material: Refers to the raw materials and components used in manufacturing.

• Method: Refers to the processes and procedures followed in production.

• Example: Ensuring the right balance of 4M factors leads to efficient production and quality output.

Screen printing plays a crucial role in industrial areas by providing a cost-effective and versatile method for printing on various materials.

• Screen printing is used for printing on a wide range of industrial products such as circuit boards, electronic components, automotive parts, textiles, glass, and ceramics.

• It allows for high-quality and durable printing, making it suitable for applications that require long-lasting markings or designs.

• Screen printing can be used for appl...read more

5S methodology enhances workplace efficiency through organization, cleanliness, and standardization.

• Sort (Seiri): Remove unnecessary items from the workspace. Example: Discarding outdated tools.

• Set in Order (Seiton): Organize tools and materials for easy access. Example: Labeling storage areas.

• Shine (Seiso): Clean the workspace regularly to maintain a safe environment. Example: Daily cleaning schedules.

• Standardize (Seiketsu): Establish standards for processes and cleanliness....read more

I create part programs for machines and select appropriate tools for the job.

• I use computer-aided manufacturing (CAM) software to create part programs for machines.

• I consider factors such as material, tooling, and machine capabilities when programming.

• I select appropriate tools for the job based on factors such as material, geometry, and surface finish requirements.

• Examples of tools I may use include drills, end mills, taps, and reamers.

• I also consider tool wear and tool life...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.

Sets, dictionaries and entities are data structures in Python with different properties and use cases.

• Sets are unordered collections of unique elements, useful for operations like union and intersection.

• Dictionaries are key-value pairs, allowing for efficient lookup and modification of values.

• Entities can refer to any object or data type in Python, including variables, functions, and classes.

• Sets and dictionaries can be created using curly braces, while entities are defined u...read more

To make changes in the shop floor, I would follow a systematic approach involving planning, communication, implementation, and evaluation.

• Develop a clear plan outlining the desired changes and objectives

• Communicate the proposed changes to the shop floor employees and stakeholders

• Implement the changes gradually, ensuring proper training and support

• Regularly evaluate the effectiveness of the changes and make necessary adjustments

• Examples: Introducing new machinery, optimizing p...read more

Automobile engineering is a branch of engineering that deals with the design, development, production, and maintenance of automobiles.

• It involves the study of various aspects of automobiles, including their structure, engines, electrical systems, and safety features.

• Automobile engineers work on designing and improving the performance, fuel efficiency, and safety of vehicles.

• They also focus on developing new technologies such as electric and autonomous vehicles.

• Examples of aut...read more

The injection molding machine is operated by a trained production engineer.

• The production engineer should have knowledge of the machine's operation and maintenance.

• They should be able to troubleshoot any issues that arise during production.

• The engineer should also be responsible for ensuring the machine is properly calibrated and producing quality products.

• Examples of tasks include setting up the machine, adjusting settings, and monitoring production.

• Regular maintenance and c...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

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

Electronic circuits do not work with AC supply because they require a constant flow of current in one direction.

• Electronic circuits are designed to work with DC (direct current) supply, where the current flows in one direction.

• AC (alternating current) constantly changes direction, causing fluctuations in the flow of current which can disrupt the operation of electronic components.

• Components like diodes and transistors in electronic circuits rely on the consistent flow of curr...read more

Production engineering involves designing, developing, and maintaining production processes and systems.

• Production engineers work to optimize production processes to increase efficiency and reduce costs.

• They collaborate with other departments to ensure that production goals are met.

• They also troubleshoot issues with production equipment and implement solutions to prevent future problems.

• Examples of production engineering projects include designing new manufacturing processes,...read more

Vernier calipers least count is the smallest measurement that can be read on the scale of the caliper.

• The least count of a Vernier caliper is typically 0.02 mm or 0.001 inches.

• It 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 1 mm and there are 50 divisions on the Vernier scale, the least count would be 0.02 mm.

Different types of valves used in industries include gate valves, globe valves, ball valves, butterfly valves, and check valves.

• Gate valves: used to control the flow of liquids or gases by opening or closing the gate.

• Globe valves: used to regulate flow in a pipeline, with a globe-shaped body and a movable plug.

• Ball valves: have a spherical closure unit to control flow, commonly used in high-pressure applications.

• Butterfly valves: have a disc that rotates to regulate flow, oft...read more

Geometrical tolerance refers to the allowable variation in dimensions and form of a part, while theoretical tolerance is the ideal or perfect value for a dimension.

• Geometrical tolerance allows for deviations in dimensions and form to ensure proper fit and function of parts.

• Theoretical tolerance represents the ideal or perfect value for a dimension, with no allowance for variation.

• Geometrical tolerance is specified using symbols like concentricity, perpendicularity, and parall...read more

Material properties such as hardness, thermal conductivity, and melting point can affect process parameters in production engineering.

• Hardness affects tool wear and machining forces

• Thermal conductivity affects heat transfer during processes like welding or casting

• Melting point determines the temperature at which materials can be processed

• Density affects material flow and formability

The required vacuum pressure for Husky robot depends on the specific application and the type of material being handled.

• The vacuum pressure required for Husky robot varies based on the size and weight of the material being handled.

• The type of vacuum pump used also affects the required pressure.

• Consult the manufacturer's specifications or an experienced production engineer for specific vacuum pressure requirements.

• Factors such as altitude and ambient temperature can also impac...read more

Conventional machining processes required after printing

• Milling

• Drilling

• Turning

• Grinding

• Boring

• Tapping

• Reaming

• Broaching

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

HRTC, MTC, Chiller, Sequencer and Robot are all equipment used in production engineering.

• HRTC (High Rate Thermo Chiller) is used for cooling high power lasers in manufacturing.

• MTC (Multi-Temperature Chiller) is used for cooling multiple machines at different temperatures.

• Chiller is used for cooling various equipment in production.

• Sequencer is used to control the sequence of operations in a manufacturing process.

• Robot is used for automation in manufacturing processes.

The acceptable percentage of rejection in production varies depending on industry standards and company goals.

• Acceptable rejection rates typically range from 1-5% in most industries.

• Some industries, such as automotive or aerospace, may have stricter standards with rejection rates below 1%.

• Continuous improvement efforts aim to reduce rejection rates over time.

• Factors like product complexity, production process, and quality control measures influence acceptable rejection rates.

Capacitor start and run motors are types of motors commonly used in various applications.

• Capacitor start motors use a capacitor to provide high starting torque and are commonly used in appliances like air conditioners and refrigerators.

• Capacitor run motors use a capacitor to improve the motor's efficiency and power factor, and are often found in fans, pumps, and compressors.

• Both types of motors have advantages and disadvantages depending on the specific application and requir...read more

Switch is used to control the flow of electricity, isolator is used for isolating a circuit, and circuit breaker is used for protecting the circuit from overloads.

• Switch is used to open or close an electrical circuit, allowing or stopping the flow of electricity.

• Isolator is used to disconnect a circuit from the power supply for maintenance or repair purposes.

• Circuit breaker is a device designed to protect an electrical circuit from damage caused by overload or short circuit.

• E...read more

Engineering drawings are detailed diagrams that communicate the design and specifications of a product or system.

• Engineering drawings are technical illustrations that provide information about dimensions, materials, and other specifications of a product or system.

• They are typically created using computer-aided design (CAD) software.

• Engineering drawings use standardized symbols and conventions to convey information clearly and accurately.

• They are essential for manufacturing, c...read more

The weight of a 1mX1mX3mm MS plate can be calculated using the formula: Weight = Length(m) x Width(m) x Thickness(mm) x Density of MS (kg/m^3)

• Convert the thickness from mm to m (3mm = 0.003m)

• Density of MS is typically around 7850 kg/m^3

• Calculate the weight using the formula: Weight = 1m x 1m x 0.003m x 7850 kg/m^3

To maintain production efficiency, it is important to focus on continuous improvement, effective planning, regular maintenance, and employee training.

• Implement lean manufacturing principles to eliminate waste and optimize processes.

• Regularly analyze production data to identify bottlenecks and areas for improvement.

• Develop and follow effective production schedules and plans.

• Ensure proper maintenance of equipment to minimize downtime.

• Invest in employee training and development ...read more

Analyzing the situation on the shop floor involves observing, identifying problems, prioritizing and taking corrective actions.

• Observe the shop floor to identify problems

• Prioritize the problems based on their impact on production

• Take corrective actions to resolve the problems

• Ensure that the corrective actions are effective and sustainable

• Continuously monitor the shop floor to identify new problems

Basic electronics devices are components used in electronic circuits to control the flow of electricity.

• Transistors

• Diodes

• Resistors

• Capacitors

• Inductors

• Integrated circuits

• Transformers

My basic engineering knowledge includes understanding of fundamental concepts, principles and theories of engineering.

• Knowledge of mathematics, physics and chemistry

• Understanding of engineering materials and their properties

• Familiarity with engineering design and analysis tools

• Knowledge of manufacturing processes and techniques

• Understanding of safety and environmental regulations

• Familiarity with project management and quality control

• Ability to read and interpret technical dra...read more

I am proficient in programming languages such as Python, Java, and C++.

• Python

• Java

• C++

I have used software to create programs.

• I have used software like AutoCAD, SolidWorks, and MATLAB to create programs for production engineering.

• Using software allows for more precise and efficient programming compared to manual methods.

• Software also helps in simulating and testing programs before implementation.

Running a plant with zero defect requires a combination of preventive measures, quality control, and continuous improvement.

• Implementing a robust quality management system

• Regular maintenance and calibration of equipment

• Training and development of employees

• Continuous monitoring and analysis of production processes

• Root cause analysis and corrective actions for any defects

• Collaboration with suppliers to ensure quality of raw materials

• Regular audits and inspections to identify ar...read more

Efficiency of a boiler can be increased by improving insulation, optimizing combustion, and regular maintenance.

• Improve insulation to reduce heat loss

• Optimize combustion by adjusting air-to-fuel ratio and using efficient burners

• Regular maintenance to clean and repair components

• Use economizers to recover waste heat

• Upgrade to high-efficiency boilers

• Implement energy management systems to monitor and control boiler operations

Production is the process of creating goods or services, while productivity measures the efficiency of production.

• Production refers to the creation of goods or services through various processes.

• Productivity is a measure of how efficiently resources are used to produce goods or services.

• Productivity can be measured by the output per unit of input, such as the number of products produced per hour of labor.

• Increasing productivity often involves improving processes, reducing was...read more

Operations on lathe machine include turning, facing, drilling, boring, threading, knurling, and parting.

• Turning: rotating the workpiece against a cutting tool to remove material and create a cylindrical shape

• Facing: cutting a flat surface perpendicular to the axis of rotation

• Drilling: creating a hole in the workpiece

• Boring: enlarging an existing hole in the workpiece

• Threading: cutting threads on the workpiece

• Knurling: creating a pattern of small ridges on the surface of the w...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

5S is a workplace organization method that aims to improve efficiency and productivity by maintaining an orderly workplace.

• Sort: Remove unnecessary items from the workplace

• Set in order: Organize the remaining items in a logical manner

• Shine: Clean and inspect the workplace regularly

• Standardize: Establish procedures and standards for maintaining the workplace

• Sustain: Continuously improve and maintain the 5S system

• Example: Implementing color-coded labels for tools and equipment

Projection welding is a type of resistance welding process used to join metal parts together.

• Projection welding involves passing a high electrical current through a small projection on one of the metal parts, creating heat at the contact point.

• The heat generated causes the metal to melt and form a weld nugget, joining the two parts together.

• This process is commonly used in automotive industry for welding nuts, bolts, and other fasteners onto metal parts.

• It is also used in man...read more

BOM stands for Bill of Materials, it is a list of all the components and parts required to manufacture a product.

• BOM is used in manufacturing to ensure all necessary components are available for production.

• It includes information such as part numbers, quantities, and descriptions.

• Structural drawings are used to depict the design and layout of a structure or product.

• WIP stands for Work in Progress, it refers to products that are in the process of being manufactured but are not...read more

A 'Why Why' analysis identifies root causes of problems by repeatedly asking 'why' to uncover underlying issues.

• Helps in identifying the root cause of a problem rather than just addressing symptoms.

• Involves asking 'why' multiple times (typically five) to drill down to the core issue.

• Example: If a machine breaks down, asking 'why' could lead to discovering inadequate maintenance practices.

• Encourages a systematic approach to problem-solving, fostering a culture of continuous im...read more

Common faults seen on site include equipment malfunctions, power outages, and human errors.

• Equipment malfunctions such as broken machinery or faulty sensors

• Power outages causing disruptions in production

• Human errors like incorrect settings or improper maintenance

• Environmental factors like extreme weather conditions affecting operations

Mass production involves producing large quantities of identical products, while batch production involves producing smaller quantities of customized products.

• Mass production focuses on efficiency and high volume production.

• Batch production allows for customization and flexibility.

• Mass production typically uses assembly lines and standardized processes.

• Batch production often requires more manual labor and specialized equipment.

• Examples of mass production include automobile ma...read more