1500+ Quality Engineer Interview Questions and Answers

List count is the number of items in a list. Vernier caliper is a tool used to measure length, width, and thickness.

• List count is determined by counting the number of items in a list.

• Vernier caliper is used to measure length, width, and thickness of an object.

• To use vernier caliper, place the object between the jaws and read the measurement on the scale.

• The vernier scale can be used to measure to a higher degree of accuracy than a regular ruler.

I will investigate the complaint thoroughly and take necessary actions to resolve the issue and prevent it from happening again.

• Listen to the customer's complaint and empathize with their situation.

• Investigate the root cause of the issue and gather all relevant information.

• Take immediate corrective actions to resolve the issue and prevent it from happening again.

• Communicate with the customer and keep them informed about the progress of the resolution.

• Follow up with the custom...read more

The 7 tank powder coating process involves seven stages of cleaning and preparation before the actual powder coating is applied.

• Degreasing

• Rinsing

• Surface conditioning

• Phosphate coating

• Rinsing

• Drying

• Powder coating

Compressure refers to the act of compressing or applying pressure to something. Working off compressure involves utilizing the energy released from the compression.

• Compressure is commonly used in manufacturing processes to shape materials such as metal or plastic.

• Working off compressure can be seen in various applications such as hydraulic systems, where pressure is used to power machinery.

• Compressure can also refer to the compression of gases, which can be used in refrigerat...read more

Concrete cover is the thickness of concrete between the surface of embedded reinforcement and the outer surface of the concrete.

• It is required to protect the reinforcement from corrosion and fire damage.

• The thickness of the concrete cover depends on the type of structure and the environmental conditions.

• The minimum concrete cover is specified in the design codes and standards.

• For example, in reinforced concrete columns, the minimum concrete cover is 40mm.

• In marine structures,...read more

To achieve required quality requirements, a quality engineer should focus on process improvement, effective communication, and continuous monitoring.

• Identify and understand the quality requirements of the product or service

• Develop and implement quality control processes and procedures

• Ensure effective communication and collaboration with stakeholders

• Monitor and measure quality metrics to identify areas for improvement

• Implement corrective actions to address quality issues

• Contin...read more

The latest edition of FMEA is the AIAG & VDA FMEA Handbook, which combines the best practices from both AIAG and VDA methodologies.

• The latest edition of FMEA is the AIAG & VDA FMEA Handbook, released in 2019.

• It combines the best practices from both AIAG and VDA methodologies.

• The new edition emphasizes risk management and prevention rather than detection.

• It includes updated severity, occurrence, and detection ratings, as well as new risk priority numbers (RPN).

There are several types of brick tests and corresponding IS codes.

• Compressive strength test (IS code: IS 3495 Part 1)

• Water absorption test (IS code: IS 3495 Part 2)

• Efflorescence test (IS code: IS 3495 Part 3)

• Dimensional tolerance test (IS code: IS 3495 Part 4)

• Warpage test (IS code: IS 3495 Part 5)

• Soundness test (IS code: IS 3495 Part 6)

• Density test (IS code: IS 3495 Part 7)

Create a 3 digit password based on given condition.

• The condition for the password is not provided.

• Without the condition, it is impossible to create a password.

• The password should be strong and not easily guessable.

Abstract class can have implementation while interface only has method signatures.

• Abstract class can have constructors while interface cannot.

• A class can implement multiple interfaces but can only inherit from one abstract class.

• Abstract class can have non-abstract methods while interface only has method signatures.

• Abstract class can have instance variables while interface cannot.

• Example of abstract class: public abstract class Shape { public abstract double area(); }

• Example ...read more

To control the defect problem, use 7QC tools and TQM.

• Identify the problem and gather data using tools like Pareto chart, Ishikawa diagram, etc.

• Analyze the data to find the root cause of the problem.

• Develop and implement a solution using Total Quality Management principles.

• Monitor and control the process to ensure the problem does not recur.

• Continuously improve the process to prevent future defects.

Changing elements like Si, Carbon, Cr in grey iron or sg iron can significantly impact mechanical properties.

• Increasing Silicon content can improve fluidity and machinability but decrease strength

• Increasing Carbon content can increase hardness and wear resistance

• Adding Chromium can improve corrosion resistance and strength

• Changing elements must be carefully balanced to achieve desired mechanical properties

Speed can be controlled by adjusting the pressure of the fluid or gas that powers the system.

• Pressure can be increased or decreased to control the speed of a system.

• This is commonly used in hydraulic and pneumatic systems.

• For example, in a hydraulic system, increasing the pressure of the fluid can increase the speed of a cylinder.

• Similarly, in a pneumatic system, increasing the pressure of the gas can increase the speed of a piston.

• Proper calibration and monitoring of pressur...read more

8D is a problem-solving methodology used to identify, correct, and prevent recurring problems.

• 8D stands for 8 Disciplines

• It is a structured approach to problem-solving

• It involves a team-based approach

• The 8 disciplines include steps such as defining the problem, identifying root cause, implementing corrective actions, and preventing recurrence

• It is commonly used in the automotive and manufacturing industries

Vena contracta is the point of minimum area in a fluid stream where the velocity is at its maximum.

• It is the point of maximum velocity in a fluid stream

• It is the point of minimum area in a fluid stream

• It is important in fluid mechanics and is used to calculate flow rate

• It is commonly used in the design of valves and orifices

SPC (Statistical Process Control) is a key tool in the Six Sigma process for monitoring and controlling process variation.

• SPC is used to collect and analyze data in real-time to ensure that a process is stable and capable of meeting customer requirements.

• It involves the use of control charts to monitor process performance and identify any special causes of variation.

• SPC helps in identifying and addressing process issues before they result in defects or non-conformance.

• By usin...read more

5S is a methodology for workplace organization and standardization. Improving quality involves identifying and eliminating waste.

• Sort - separate necessary items from unnecessary ones

• Set in order - arrange necessary items in a logical and efficient manner

• Shine - clean and inspect the workplace regularly

• Standardize - establish procedures and guidelines for maintaining the workplace

• Sustain - ensure that the 5S system is continuously implemented and improved

• Identify and eliminate...read more

Functional testing focuses on verifying that the software functions as expected, while non-functional testing focuses on aspects like performance, usability, and security.

• Functional testing ensures that the software meets the specified requirements and functions correctly.

• Non-functional testing evaluates aspects like performance, usability, reliability, and security.

• Examples of functional testing include unit testing, integration testing, and system testing.

• Examples of non-fu...read more

Annealing, quenching, acid pickling, and bright annealing are heat treatment processes used to alter the properties of metals.

• Annealing involves heating a metal to a specific temperature and then slowly cooling it to make it softer and more ductile.

• Quenching is the rapid cooling of a metal to increase its hardness and strength.

• Acid pickling is a process of removing impurities and scale from the surface of a metal using acid solutions.

• Bright annealing is a heat treatment proce...read more

The elongation percentage of 316L grade Steel is typically around 55%.

• 316L grade Steel typically has an elongation percentage of around 55%

• Elongation percentage indicates the amount of deformation a material can undergo before breaking

• Higher elongation percentage indicates better ductility and toughness of the material

The percentage of Nickel present in 304 Grade Steel is approximately 8-10%.

• 304 Grade Steel contains around 8-10% Nickel.

• Nickel is added to steel to improve its corrosion resistance.

• The exact percentage may vary slightly depending on the specific composition of the steel.

To convince the client about performance testing, emphasize its benefits and provide examples of how it can improve their product.

• Explain the importance of performance testing in ensuring the product meets performance requirements and user expectations.

• Highlight the potential risks of not conducting performance testing, such as poor user experience, system crashes, and loss of customers.

• Share success stories or case studies where performance testing identified and resolved cr...read more

MFI is Melt Flow Index, Density is mass per unit volume, Latest version of ISO is ISO 9001:2015, 5-S & Kaizen are Lean Manufacturing tools.

• Melt Flow Index (MFI) is a measure of the ease of flow of the melt of a thermoplastic polymer.

• Density is the mass per unit volume of a substance.

• ISO 9001:2015 is the latest version of the ISO 9001 standard for Quality Management Systems.

• 5-S is a Lean Manufacturing tool that stands for Sort, Set in Order, Shine, Standardize, and Sustain.

• Kai...read more

Cookies-Cache memory is a storage mechanism used by web browsers to store website data for faster access.

• Cookies are small text files that are stored on a user's device by a website.

• They contain information such as user preferences, login credentials, and browsing history.

• Cookies are sent by the web server to the browser and are stored locally on the device.

• When a user visits a website again, the browser sends the stored cookies back to the server.

• This allows the server to pe...read more

A six stroke engine is an internal combustion engine that has six strokes in its cycle instead of the traditional four strokes.

• The six stroke engine was developed to improve fuel efficiency and reduce emissions.

• It adds an additional power and exhaust stroke to the traditional four stroke cycle.

• The additional strokes are achieved by adding a second set of valves and an additional cylinder.

• The six stroke engine can be configured to run on various fuels, including gasoline, dies...read more

There are 5 levels in PPAP (Production Part Approval Process).

• PPAP has 5 levels: Level 1, Level 2, Level 3, Level 4, and Level 5.

• Each level represents a different stage of the PPAP process.

• Level 1 includes documentation submission, while Level 5 involves customer approval.

• The higher the level, the more comprehensive the PPAP requirements become.

• PPAP is used to ensure that suppliers meet the quality standards of their customers.

Quantity of different mix designs, couplers, and their codes can be found by referring to relevant standards and specifications.

• Refer to relevant standards and specifications for mix designs and couplers

• Check the quantity requirements specified in the project documents

• Consult with suppliers or manufacturers for information on mix designs and couplers

• Use testing and sampling methods to verify the quality of mix designs and couplers

To reduce defects in product, we can implement quality control measures and use statistical process control tools.

• Implement quality control measures such as inspection, testing, and process control

• Use statistical process control tools to monitor and improve the production process

• Identify and address root causes of defects through root cause analysis

• Train employees on quality control and process improvement techniques

• Collaborate with suppliers to improve the quality of raw mat...read more

CAPA stands for Corrective and Preventive Action. It is a systematic approach to investigate and address quality issues.

• CAPA is a process used to identify, investigate, and correct quality issues in a systematic manner.

• The format of a CAPA typically includes identifying the issue, root cause analysis, corrective actions, preventive actions, and verification of effectiveness.

• For the latest customer complaint, the action plan would involve investigating the complaint, identifyi...read more

GD&T stands for Geometric Dimensioning and Tolerancing. It is used to define and communicate engineering tolerances.

• GD&T is a symbolic language used to specify the size, shape, orientation, and location of features on a part.

• It ensures that parts are manufactured to the correct dimensions and fit together properly.

• GD&T is used in quality to improve communication between design, engineering, and manufacturing teams.

• It helps to reduce errors, increase efficiency, and improve pr...read more

QMS stands for Quality Management System. It is a set of policies, processes, and procedures required for planning and execution of quality control.

• QMS ensures that the products or services meet the customer's requirements and comply with the regulatory standards.

• It involves continuous improvement of processes and products to enhance customer satisfaction.

• QMS includes activities such as quality planning, quality control, quality assurance, and quality improvement.

• ISO 9001 is ...read more

Validation ensures the product meets the customer's needs, while verification ensures the product is built correctly.

• Validation is the process of evaluating a product to ensure it meets the customer's requirements and needs.

• Verification is the process of evaluating whether a product is built correctly according to the specifications and requirements.

• Validation answers the question 'Are we building the right product?' while verification answers 'Are we building the product rig...read more

FIP stands for Fixed Index Annuity.

• FIP is a type of annuity that offers a guaranteed minimum interest rate.

• The interest rate is linked to a stock market index, such as the S&P 500.

• The interest rate is fixed for a certain period of time, usually several years.

• FIPs are often used as a retirement savings vehicle.

• They offer the potential for higher returns than traditional fixed annuities, but with less risk than investing directly in the stock market.

Postman is used for API testing. GUI testing involves testing the user interface while API testing involves testing the backend functionality.

• Postman is a tool used for testing APIs by sending requests and receiving responses.

• GUI testing involves testing the user interface, such as buttons, forms, and menus.

• API testing involves testing the backend functionality, such as data validation and response time.

• Postman can be used to test APIs by sending requests and receiving respon...read more

Quality is meeting or exceeding customer expectations. Various gauges are used to measure quality. The unit of air pressure is typically measured in psi or pascals.

• Quality is the degree to which a product or service meets or exceeds customer expectations.

• Various gauges such as calipers, micrometers, and CMMs are used to measure quality in manufacturing processes.

• The unit of air pressure is typically measured in pounds per square inch (psi) or pascals (Pa).

CP/CPk measures process capability while fishbone diagram is a root cause analysis tool.

• CP/CPk is used to measure the ability of a process to produce products within specification limits

• Fishbone diagram is a visual tool used to identify the root cause of a problem

• CP is used for a stable process while CPk is used for an unstable process

• Fishbone diagram is also known as Ishikawa diagram or cause-and-effect diagram

• CP/CPk is a statistical tool while fishbone diagram is a quality ...read more

GD&T stands for Geometric Dimensioning and Tolerancing. The 7 QC tools are used for quality control, and the 5 core tools are used for quality engineering.

• GD&T is a system of symbols and rules used to define and communicate engineering tolerances.

• It ensures that parts and assemblies are manufactured and inspected correctly.

• The 7 QC tools are: Pareto Chart, Cause and Effect Diagram, Check Sheet, Control Chart, Histogram, Scatter Diagram, and Stratification.

• These tools help ide...read more

The accept table value in Statistical Process Control (SPC) is a reference table used to determine whether a process is within acceptable limits.

• The accept table value in SPC is used to compare the calculated control limits with the actual process data.

• It helps in determining if the process is stable and producing acceptable results.

• The accept table value is typically based on statistical calculations and can vary depending on the desired level of control and confidence.

• For e...read more

Calibration ensures accuracy of measurement devices, while validation ensures that a process or system meets requirements.

• Calibration involves adjusting a device to ensure it provides accurate measurements.

• Validation involves testing a process or system to ensure it meets predetermined requirements or specifications.

• Calibration is typically done on measurement devices such as thermometers, scales, and gauges.

• Validation is typically done on processes or systems such as manufac...read more

8D is a problem-solving methodology used in quality management to identify, correct, and prevent recurring problems.

• 8D stands for 8 disciplines, each representing a step in the problem-solving process.

• Containment action is taken in the 2nd discipline of 8D to prevent the issue from causing further problems.

• Examples of containment actions include implementing temporary fixes, isolating affected products, and stopping production of defective parts.

MSA is implemented in automotive industry to ensure the accuracy and reliability of measurement systems.

• To ensure the quality and consistency of products in automotive manufacturing

• To identify and eliminate sources of variation in measurement processes

• To meet customer requirements and industry standards

• To improve overall process efficiency and reduce waste

• Examples: Using MSA to validate the accuracy of testing equipment for engine components

Quality is meeting or exceeding customer expectations through consistent and reliable products or services.

• Quality is a measure of how well a product or service meets customer needs and expectations.

• It involves ensuring that products or services are consistent and reliable.

• Quality is achieved through a combination of processes, systems, and people.

• Mechanical engineering is a field that focuses on designing and developing mechanical systems and products that meet quality stand...read more

Precision is better for process accuracy as it focuses on consistency and repeatability.

• Precision ensures that measurements or results are consistently close to each other.

• Accuracy refers to how close a measurement is to the true value.

• A process can be precise but not accurate if the measurements are consistently off by the same amount.

• For example, in manufacturing, precision is crucial for ensuring consistent product quality.

• Accuracy is important in fields like medicine wher...read more

Grain structures of steel change at different temperatures affecting its properties.

• At room temperature, steel has a fine grain structure which provides good strength and toughness.

• As temperature increases, the grain size also increases, leading to reduced strength and toughness.

• At high temperatures, steel can have a coarse grain structure which may result in lower mechanical properties.

• Grain refinement techniques like controlled rolling can be used to improve the properties ...read more

The final/finished product temperature of Rebar is typically room temperature.

• Rebar is typically stored and used at room temperature

• The temperature of Rebar can vary depending on the environment it is stored in

• Rebar is not typically heated or cooled as part of the manufacturing process

Cut the cake into quarters in the first attempt, then stack the quarters and cut them in half in the second attempt, resulting in 8 pieces.

• Cut the cake into quarters in the first attempt

• Stack the quarters on top of each other and cut them in half in the second attempt

• You will have 8 pieces of cake after the third attempt

I follow the ISO 9001:2015 code for quality management systems.

• ISO 9001:2015 is an international standard for quality management systems.

• It provides a framework for organizations to consistently meet customer requirements and enhance customer satisfaction.

• The standard focuses on process improvement, risk management, and continuous monitoring and evaluation.

• By following ISO 9001:2015, I ensure adherence to best practices and drive quality improvement in my work.