50+ Production Incharge Interview Questions and Answers

Managing a plant with new people and in a new country requires effective communication, cultural sensitivity, and adaptability.

• Establish clear communication channels to ensure all team members understand their roles and responsibilities.

• Provide cultural sensitivity training to help employees understand and respect each other's differences.

• Encourage team building activities to foster a sense of unity and collaboration among the diverse workforce.

• Adapt to local regulations and ...read more

Increasing production while maintaining quality of cement requires optimizing processes, using high-quality raw materials, and implementing quality control measures.

• Optimize production processes to reduce waste and increase efficiency

• Use high-quality raw materials to ensure consistency and quality of the final product

• Implement quality control measures such as regular testing and inspections to identify and address any issues

• Invest in modern technology and equipment to improve...read more

Yes, I have knowledge of PLC & SCADA and can operate and maintain machines.

• I have completed a course on PLC & SCADA and have hands-on experience in operating and maintaining machines.

• I am familiar with programming languages used in PLC & SCADA systems.

• I have experience in troubleshooting and resolving issues related to machines.

• I am well-versed in reading and interpreting technical manuals and schematics.

• I have worked with various types of machines such as CNC machines, conve...read more

Increasing employee engagement and reducing attrition can be achieved through various strategies such as fostering a positive work culture, providing opportunities for growth and development, and recognizing and rewarding employees.

• Foster a positive work culture by promoting open communication, collaboration, and inclusivity

• Provide opportunities for growth and development through training programs, mentorship, and career advancement

• Recognize and reward employees for their har...read more

Machines can be run by training other employees or hiring temporary operators.

• Train other employees to operate the machines in case of absence of the machine operator.

• Hire temporary operators from agencies to run the machines temporarily.

• Implement automated systems or self-operating machines to reduce dependency on human operators.

• Cross-train existing employees to handle multiple roles in the production process.

Recrystallisation is the process of heating and cooling a metal to remove impurities and improve its strength and ductility.

• Heating the metal to a specific temperature to dissolve impurities

• Cooling the metal slowly to allow new, pure crystals to form

• Improves the metal's strength, ductility, and other mechanical properties

• Used in the production of high-quality metals for various industries

• Examples include the recrystallisation of steel, aluminum, and copper

Addressing underperformance involves identifying the root cause, setting clear expectations, providing support and feedback, and taking appropriate action if necessary.

• Identify the root cause of underperformance

• Set clear expectations and goals for improvement

• Provide support and resources to help employees improve

• Give regular feedback and monitor progress

• Take appropriate action if necessary, such as coaching, training, or disciplinary measures

We can handle machine without production loss by having backup power sources and implementing emergency protocols.

• Have backup power sources like generators or UPS systems

• Implement emergency protocols to quickly switch to backup power

• Train employees on emergency procedures

• Regularly test backup power sources and emergency protocols

• Consider investing in renewable energy sources for backup power

• Examples: hospitals have backup generators to ensure continuous power supply for criti...read more

You can do two recorders class live in Vmix software by setting up multiple inputs and configuring them accordingly.

• Set up two separate inputs for each recorder class

• Configure the settings for each input such as audio, video, and recording options

• Ensure that both inputs are active and ready to record simultaneously

I have handled multiple machines and operators in my role as a Production Incharge.

• I have managed a team of 10 operators and supervised the operation of 5 machines.

• I ensured smooth coordination between operators and machines to maximize productivity.

• I implemented training programs to enhance operator skills and improve machine efficiency.

• I regularly monitored machine performance and conducted maintenance to minimize downtime.

• I maintained records of machine utilization and ope...read more

To create a process flow diagram from a physical component, start by identifying the inputs, processes, and outputs involved.

• Identify the physical component and its function

• List all the inputs required for the component to function

• Map out the processes involved in transforming the inputs into outputs

• Identify the outputs produced by the component

• Connect the inputs, processes, and outputs in a sequential flow diagram

• Label each step in the process flow diagram for clarity

Planning plays a crucial role in production by ensuring efficient utilization of resources and meeting production targets.

• Planning helps in determining the production targets and timelines.

• It helps in identifying the resources required for production such as raw materials, labor, and machinery.

• Planning also helps in scheduling the production process to ensure timely delivery of products.

• It helps in minimizing wastage and reducing production costs.

• Effective planning can also h...read more

Plywood is a type of engineered wood made from thin layers of wood veneer that are glued together.

• Plywood is made by stacking thin layers of wood veneer, with each layer's grain perpendicular to the adjacent layer.

• It is commonly used in construction, furniture making, and packaging.

• Plywood is available in different grades, with varying thicknesses and sizes.

• It is known for its strength, durability, and resistance to warping and cracking.

• Plywood can be made from a variety of w...read more

Air compressor load requirements can be calculated by considering factors such as air demand, duty cycle, and pressure requirements.

• Determine the required air demand by assessing the total air consumption of all connected equipment.

• Consider the duty cycle, which is the percentage of time the compressor will be running.

• Calculate the pressure requirements based on the highest pressure needed for any equipment or process.

• Use the following formula to calculate the air compressor ...read more

Cylinder manufacturing process involves several steps from raw material to finished product.

• The process starts with the selection of raw material such as steel or aluminum.

• The raw material is then cut into appropriate sizes and shapes.

• The next step involves heating the material to a specific temperature to make it malleable.

• The heated material is then placed in a cylinder-shaped mold and pressed to form the desired shape.

• The cylinder is then cooled and undergoes various finis...read more

Pressure vessel manholes are round-shaped for safety and structural integrity.

• Round shape distributes stress evenly, reducing the risk of failure.

• Round shape allows for better sealing and pressure containment.

• Round shape is easier to manufacture and install compared to other shapes.

• Round shape minimizes the risk of sharp corners or edges that could cause injury.

• Round shape is more resistant to deformation under pressure compared to other shapes.

• Round shape allows for easier a...read more

Cement density is calculated by dividing the mass of cement by its volume.

• Cement density is expressed in kg/m³.

• The mass of cement can be determined by weighing it on a scale.

• The volume of cement can be calculated by measuring its displacement in water.

• The formula for calculating cement density is: Density = Mass/Volume.

• The density of cement can vary depending on factors such as the type of cement and its moisture content.

Pressure unit conversion involves converting one unit of pressure to another unit.

• Pressure can be measured in various units such as pascal (Pa), bar, psi, atmosphere (atm), etc.

• To convert between units, you need to know the conversion factors.

• For example, to convert from psi to bar, multiply the psi value by 0.0689476.

• To convert from bar to pascal, multiply the bar value by 100,000.

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

• It involves creating a plan for production based on demand and available resources.

• It also involves scheduling production activities and monitoring progress to ensure timely delivery.

• Effective production planning and control can help reduce costs, improve efficiency, and increase customer satisfaction.

• Examples include creating a production schedule for a manufacturing plant, manag...read more

Machine maintenance can be managed by implementing a preventive maintenance schedule, training staff on proper maintenance procedures, keeping detailed records, and regularly inspecting machines.

• Implement a preventive maintenance schedule to regularly check and maintain machines.

• Train staff on proper maintenance procedures to ensure machines are cared for correctly.

• Keep detailed records of maintenance activities, including dates, tasks performed, and any issues encountered.

• Re...read more

The pillars in TPM are the foundational elements that support the implementation and success of Total Productive Maintenance.

• 1. Jishu Hozen (Autonomous Maintenance): Operators are responsible for routine maintenance tasks and inspections to prevent breakdowns.

• 2. Kobetsu Kaizen (Focused Improvement): Continuous improvement activities focused on specific areas to eliminate waste and improve productivity.

• 3. Planned Maintenance: Scheduled maintenance activities to ensure equipmen...read more

The chemicals used for NBR (nitrile butadiene rubber) and NR (natural rubber) production vary.

• NBR is produced using chemicals such as acrylonitrile and butadiene.

• NR is produced using latex obtained from the Hevea brasiliensis tree.

• Additional chemicals like sulfur, accelerators, and antioxidants may be used in the production process.

OEE stands for Overall Equipment Efficiency. It is a measure of how effectively a production line or machine is utilized.

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

• Availability measures the actual production time compared to the planned production time.

• Performance measures the actual production rate compared to the ideal production rate.

• Quality measures the good units produced compared to the total units produced.

• OEE = Availability x Perfo...read more

Polymers are large molecules made up of repeating subunits called monomers. They have a wide range of applications in various industries.

• Polymers are used in the production of plastics, fibers, adhesives, and coatings.

• They can be natural, like proteins and DNA, or synthetic, like polyethylene and PVC.

• The properties of polymers can be tailored to suit specific applications by adjusting their chemical composition and molecular structure.

• Polymers can be classified based on their...read more

The mixing time in a kneader depends on the specific requirements of the production process. The melting point temperature varies depending on the material being processed.

• The mixing time in a kneader can vary based on factors such as the type of material being mixed, desired consistency, and production volume.

• The melting point temperature can vary depending on the specific material being melted, such as different types of plastics or metals.

• The mixing time and melting point ...read more

Ball mill is a versatile and efficient grinding tool with many advantages.

• Can grind a wide range of materials

• Produces fine and uniform particles

• Low cost and easy maintenance

• Can be used for both wet and dry grinding

• Can be operated continuously or intermittently

Managing language in production involves clear communication, documentation, and training.

• Establish clear communication channels for all team members

• Document processes and procedures to ensure consistency

• Provide training and resources for language skills improvement

• Encourage open communication and feedback among team members

AM step in TPM refers to Autonomous Maintenance, which involves operators taking responsibility for routine maintenance tasks.

• Autonomous Maintenance (AM) is a key step in Total Productive Maintenance (TPM) implementation.

• AM involves operators taking responsibility for routine maintenance tasks.

• Operators are trained to perform basic maintenance activities like cleaning, inspection, lubrication, and tightening.

• AM aims to prevent equipment deterioration, breakdowns, and defects....read more

Cycle time is the total time required to complete a process or task, from start to finish.

• Cycle time measures the efficiency of a production process.

• It includes both the processing time and any waiting or idle time.

• Cycle time can be used to identify bottlenecks and improve productivity.

• For example, in manufacturing, cycle time can refer to the time it takes to produce one unit of a product.

• In software development, cycle time can refer to the time it takes to complete a specif...read more

The refrigerator cycle is a thermodynamic cycle that allows a refrigerator to remove heat from a low-temperature reservoir and transfer it to a high-temperature reservoir.

• The cycle typically consists of four processes: compression, condensation, expansion, and evaporation.

• During compression, the refrigerant gas is compressed, which increases its temperature and pressure.

• In the condensation process, the hot refrigerant gas releases heat to the surroundings and condenses into a...read more

Fabric quality plays a crucial role in determining the overall quality of the garments.

• The type of fabric used affects the comfort and durability of the garment.

• The color fastness and shrinkage of the fabric can impact the appearance and fit of the garment.

• The texture and weight of the fabric can also affect the drape and overall look of the garment.

• For example, a cotton shirt made with high-quality, tightly woven fabric will be more comfortable and durable than a shirt made ...read more

A transformer is an electrical device that transfers electrical energy between two or more circuits through electromagnetic induction.

• Transformers are used to increase or decrease the voltage in electrical power applications.

• They consist of two coils of wire, known as the primary and secondary windings, wrapped around a core made of ferromagnetic material.

• Examples of transformers include power transformers used in electrical substations and distribution transformers used in h...read more

Ohm's law formula states that the current flowing through a conductor is directly proportional to the voltage across it and inversely proportional to its resistance.

• Ohm's law formula: V = I * R

• V represents voltage in volts, I represents current in amperes, and R represents resistance in ohms

• The formula can be rearranged to find current (I = V / R) or resistance (R = V / I)

• Ohm's law is commonly used in electrical engineering to calculate the relationship between voltage, curre...read more

Yes, SOPs are Standard Operating Procedures that define the steps to be followed for a particular process.

• SOPs are written documents that provide a step-by-step guide for a process.

• They ensure consistency and quality in the output of a process.

• SOPs are used in various industries such as manufacturing, healthcare, and food processing.

• Examples of SOPs include cleaning procedures, equipment operation procedures, and safety procedures.

• SOPs are regularly reviewed and updated to en...read more

Grinding media refers to the balls, rods, or other materials used to aid in the grinding process of minerals, cement, and other materials.

• Grinding media can be made of various materials such as steel, ceramic, and plastic.

• The size and shape of the grinding media can affect the efficiency of the grinding process.

• Grinding media is used in industries such as mining, cement, and chemical processing.

• Examples of grinding media include steel balls, ceramic beads, and alumina cylinde...read more

Ohm's law states that the current flowing through a conductor is directly proportional to the voltage across it, and inversely proportional to the resistance of the conductor.

• Ohm's law is represented by the formula V = I * R, where V is voltage, I is current, and R is resistance.

• It helps in calculating the current, voltage, or resistance in a circuit when the other two values are known.

• For example, if a circuit has a voltage of 12 volts and a resistance of 4 ohms, the current...read more

Rubber types include natural rubber, synthetic rubber, and specialty rubbers. Mixing procedures involve compounding, milling, and vulcanization.

• Natural rubber is derived from latex obtained from rubber trees.

• Synthetic rubber is made from petroleum-based materials and can be customized for specific applications.

• Specialty rubbers include neoprene, silicone, and butyl rubber.

• Compounding involves blending rubber with various additives like fillers, accelerators, and curing agents...read more

Normality is a measure of concentration used in chemistry, representing the number of equivalents of a substance per liter of solution.

• Normality is expressed in units of equivalents per liter (eq/L) or N.

• It is commonly used in acid-base chemistry to quantify the concentration of acids or bases in a solution.

• Normality is calculated by multiplying the molarity of a solution by the number of equivalents of the solute.

• For example, a 1M solution of HCl (hydrochloric acid) would ha...read more

pH value is a measure of the acidity or alkalinity of a solution on a scale of 0 to 14.

• pH value below 7 indicates acidity, while above 7 indicates alkalinity

• Pure water has a pH of 7, which is considered neutral

• Examples of pH values: Lemon juice (pH 2), Milk (pH 6.5), Ammonia (pH 11)

To do prod planned, you need to create a production plan that outlines the tasks, resources, and timeline for completing the production process.

• Identify the production requirements and goals

• Determine the necessary resources, such as materials, equipment, and manpower

• Create a detailed production schedule, including start and end dates for each task

• Allocate resources effectively to ensure smooth workflow

• Monitor progress and make adjustments as needed

• Communicate the production p...read more

Budgeting involves creating a financial plan for a specific period, estimating income and expenses, and allocating resources accordingly.

• Identify financial goals and objectives

• Estimate income and expenses

• Allocate resources based on priorities

• Monitor and review the budget regularly

• Make adjustments as necessary

TQM stands for Total Quality Management. Production planning involves creating a detailed plan of how to produce goods efficiently.

• TQM focuses on improving quality at every level of the production process

• It involves continuous improvement, employee involvement, and customer satisfaction

• Production planning includes setting production goals, scheduling tasks, and allocating resources

• It aims to optimize production processes to meet demand and minimize costs

FMEA stands for Failure Mode and Effects Analysis.

• FMEA is a systematic approach to identifying and preventing potential failures in a process or product.

• It involves identifying potential failure modes, determining their effects, and developing actions to prevent or mitigate those effects.

• FMEA is commonly used in manufacturing, engineering, and healthcare industries.

• Example: A car manufacturer might use FMEA to identify potential failure modes in a new engine design, such as o...read more

A thermostat works by sensing the temperature in a room and activating heating or cooling systems to maintain a desired temperature.

• Thermostat senses the temperature in a room using a sensor

• It compares the current temperature to the desired temperature set by the user

• If the current temperature is higher than the desired temperature, the thermostat activates the cooling system

• If the current temperature is lower than the desired temperature, the thermostat activates the heating...read more

Parameters of a lathe machine include spindle speed, feed rate, depth of cut, and tool selection.

• Spindle speed determines the rotational speed of the workpiece

• Feed rate controls the rate at which the cutting tool moves along the workpiece

• Depth of cut determines the amount of material removed in a single pass

• Tool selection depends on the material being machined and the desired finish

• Other parameters include coolant flow rate, tool wear monitoring, and workpiece positioning

Cutting mack to parts is a crucial task in production process.

• The process involves using cutting tools and machines to divide the mack into smaller parts.

• The parts are then inspected for quality and accuracy before being used in the production process.

• The cutting process should be done with precision to avoid wastage of material and ensure maximum utilization.

• Proper safety measures should be taken while handling the cutting tools and machines.

• Regular maintenance of the cuttin...read more

HIRA stands for Hazard Identification and Risk Assessment.

• HIRA is a systematic process used to identify potential hazards and assess the associated risks in a workplace or production environment.

• It involves identifying hazards, evaluating the risks, and implementing control measures to mitigate those risks.

• HIRA helps in creating a safer work environment, preventing accidents, and ensuring compliance with safety regulations.

• Examples of hazards that can be identified through HI...read more