1500+ Quality Engineer Interview Questions and Answers

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

• GD&T is a symbolic language used to specify the dimensions, tolerances, and geometric characteristics of a part

• It helps ensure that parts are manufactured and assembled correctly, leading to improved quality and functionality

• GD&T uses symbols, such as concentricity, perpendicularity, and flatness, to define the allowable variations in a part's geometry

• I...read more

Steel is an alloy of iron and carbon, while stainless steel is a type of steel with added chromium for corrosion resistance. Types of steel include carbon steel, alloy steel, and tool steel.

• Steel is an alloy of iron and carbon

• Stainless steel contains chromium for corrosion resistance

• Types of steel include carbon steel, alloy steel, and tool steel

Nitrogen pinholes are typically smaller and more numerous compared to hydrogen pinholes.

• Nitrogen pinholes are usually smaller in size and more numerous than hydrogen pinholes.

• Hydrogen pinholes are larger in size and less frequent than nitrogen pinholes.

• Nitrogen pinholes are commonly found in aluminum castings, while hydrogen pinholes are more common in steel castings.

Process parameters such as temperature, pressure, and time can significantly impact the mechanical properties of a material.

• Temperature: Higher temperatures can increase ductility but decrease strength.

• Pressure: Higher pressure can improve density and strength.

• Time: Longer processing times can lead to better homogeneity and mechanical properties.

• Example: Heat treatment of steel involves specific temperature and time parameters to achieve desired mechanical properties.

GTP of 5MVA Power Transformers refers to the Guaranteed Technical Particulars.

• GTP includes specifications such as rated power, voltage ratio, impedance, and losses.

• It is a contractual agreement between the manufacturer and the customer.

• GTP ensures that the transformer meets the required performance standards.

• For a 5MVA transformer, the GTP would specify details such as 11kV/433V voltage ratio, 6% impedance, and 2.5% losses.

Draft an email to send to a supplier for a complaint related issue.

• Start with a polite greeting and introduce yourself.

• Clearly state the reason for the complaint and provide specific details.

• Include any relevant documentation or evidence to support your claim.

• Request a prompt resolution and provide a deadline if necessary.

• End the email with a polite closing and thank the supplier for their attention.

7 QC tools and SPC are essential quality control techniques used in manufacturing and other industries.

• 7 QC tools include Pareto chart, cause-and-effect diagram, control chart, histogram, scatter diagram, flowchart, and check sheet.

• SPC involves statistical analysis of data to identify and control process variation.

• Both techniques are used to improve quality, reduce defects, and increase efficiency.

• They are widely used in industries such as automotive, electronics, and healthc...read more

Confidence is belief in oneself while overconfidence is excessive belief in oneself.

• Confidence is a positive trait that helps individuals achieve their goals.

• Overconfidence can lead to underestimating risks and making mistakes.

• Confidence is based on experience and knowledge while overconfidence is based on assumptions and arrogance.

• Confidence is important in the workplace while overconfidence can lead to conflicts and poor decision-making.

• Examples of confidence include speaki...read more

The major phases of quality are planning, assurance, control, and improvement.

• Planning phase involves defining quality standards and creating a plan to achieve them.

• Assurance phase involves implementing the plan and ensuring that the standards are met.

• Control phase involves monitoring and measuring the quality of the product or service.

• Improvement phase involves analyzing data and making changes to improve quality.

• Examples of quality tools used in these phases include Six Sig...read more

The seven QC tools are basic statistical tools used to identify and solve quality problems.

• Check sheets - used to collect data in a structured manner

• Pareto charts - used to identify the most frequent problems

• Histograms - used to show the distribution of data

• Cause-and-effect diagrams - used to identify the root cause of a problem

• Control charts - used to monitor a process over time

• Scatter diagrams - used to show the relationship between two variables

• Flowcharts - used to show th...read more

Severity in PFMEA is declared based on the potential impact of a failure mode on the overall process or product.

• Severity is typically rated on a scale from 1 to 10, with 1 being the least severe and 10 being the most severe.

• Consider the consequences of a failure mode on customer safety, regulatory compliance, product functionality, and overall process performance.

• Examples of high severity failure modes include those that could result in serious injury or death, non-compliance...read more

Chemical properties refer to the behavior of materials in different chemical environments, while mechanical properties refer to how materials respond to applied forces.

• Chemical properties include corrosion resistance, chemical stability, and reactivity with other substances.

• Mechanical properties include strength, hardness, ductility, and toughness.

• Different grades of casting materials will have varying chemical and mechanical properties based on their composition and processi...read more

Electronics deals with the flow of electrons, while electrical focuses on the generation, distribution, and use of electricity.

• Electronics is concerned with the behavior and control of electrons in devices and systems.

• Electrical engineering deals with the generation, transmission, and use of electrical power.

• Electronics involves designing and building electronic circuits and devices, such as computers and smartphones.

• Electrical engineering includes working with power systems,...read more

7 QC tools include Pareto chart, fishbone diagram, scatter diagram, etc. 5 core tools include APQP, PPAP, FMEA, MSA, and SPC.

• 7 QC tools: Pareto chart, fishbone diagram, scatter diagram, control chart, histogram, check sheet, and stratification.

• 5 core tools: Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP), Failure Mode and Effects Analysis (FMEA), Measurement Systems Analysis (MSA), and Statistical Process Control (SPC).

Electronics components include resistors, capacitors, diodes, transistors, integrated circuits, and more.

• Resistors

• Capacitors

• Diodes

• Transistors

• Integrated circuits

The 5 core tools of Quality are essential techniques used in quality management to ensure products and processes meet standards.

• 1. Process Flowcharts: Used to visually represent the steps in a process.

• 2. Cause and Effect Diagrams (Fishbone Diagrams): Used to identify and analyze potential causes of a problem.

• 3. Control Charts: Used to monitor process variation over time.

• 4. Check Sheets: Used to collect and analyze data in a systematic way.

• 5. Pareto Charts: Used to prioritize ...read more

Bolt grade refers to the strength and hardness of a bolt. It is indicated by a number stamped on the head of the bolt.

• Bolt grade is determined by the material and manufacturing process of the bolt.

• Higher grade bolts are stronger and can withstand more stress.

• Bolt grade is indicated by a number stamped on the head of the bolt, such as 8.8 or 10.9.

• The first number indicates the ultimate tensile strength in MPa, while the second number indicates the yield strength in MPa.

To improve quality, implement 8D report, 5S, and 3C in our organization.

• Create a team to investigate and solve problems using 8D report.

• Implement 5S methodology to organize workplace and improve efficiency.

• Use 3C (Cause, Countermeasure, Confirm) to identify root cause and prevent recurrence.

• Train employees on these methodologies to ensure successful implementation.

• Regularly review and update processes to maintain effectiveness.

Questions related to 7QC tools, least count of vernier and micrometer, control plan, and audit type.

• 7QC tools are a set of techniques used for process improvement and problem-solving.

• Least count of vernier and micrometer is the smallest measurement that can be read on the scale.

• Control plan is a document that outlines the steps to be taken to maintain quality control during the manufacturing process.

• There are different types of audits such as internal, external, and supplier ...read more

Assembly line rejection can occur due to various reasons such as faulty equipment, human error, incorrect materials, and inadequate training.

• Faulty equipment can cause defects in the products being assembled

• Human error such as incorrect assembly or misplacement of parts can lead to rejection

• Incorrect materials or parts can cause defects or malfunctions in the final product

• Inadequate training of assembly line workers can lead to errors and defects

• Lack of quality control measur...read more

1 mm is equal to 1000 microns.

• 1 mm is equivalent to 1000 micrometers or microns.

• Micron is a unit of measurement used to measure very small distances or thicknesses.

• For example, if you have a sheet of paper that is 0.1 mm thick, it would be 100 microns thick.

Defect control can be achieved through various methods such as statistical process control, root cause analysis, and continuous improvement.

• Implement statistical process control to monitor and control the production process

• Conduct root cause analysis to identify the underlying causes of defects and implement corrective actions

• Implement continuous improvement initiatives to prevent defects from occurring in the first place

• Train employees on quality control techniques and encou...read more

IS 456 is a code of practice for the design and construction of reinforced concrete structures.

• IS 456 provides guidelines for the use of plain and reinforced concrete in construction.

• It specifies the minimum grade of concrete, reinforcement details, and design requirements.

• The code also covers the durability, workability, and strength of concrete.

• For example, it recommends a minimum grade of M20 for reinforced concrete and M15 for plain concrete.

• It also specifies the minimum ...read more

Lab tests used for material testing

• Tensile strength test

• Hardness test

• Impact test

• Fatigue test

• Creep test

4M, 5S, APQP, PPAP, and Quality Circle are all quality management tools used in manufacturing.

• 4M stands for Man, Machine, Material, and Method and is used to identify the root cause of a problem.

• 5S is a workplace organization method that stands for Sort, Set in Order, Shine, Standardize, and Sustain.

• APQP stands for Advanced Product Quality Planning and is a framework used to ensure quality in new product development.

• PPAP stands for Production Part Approval Process and is used...read more

7QC refers to the seven basic quality control tools used in quality management. The 5 core tools are key techniques for quality improvement.

• 7QC includes tools like Pareto chart, cause-and-effect diagram, control chart, scatter diagram, histogram, check sheet, and flowchart.

• 5 core tools consist of process flowchart, cause-and-effect diagram, control chart, histogram, and scatter diagram.

• These tools help in identifying, analyzing, and solving quality-related issues in a systema...read more

Metrology is the science of measurement, while Quality Engineering focuses on ensuring products meet quality standards.

• Metrology involves the study of measurement techniques, tools, and standards.

• Quality engineering focuses on designing, implementing, and maintaining quality systems to ensure products meet customer requirements.

• Metrology is more focused on the accuracy and precision of measurements, while quality engineering looks at overall product quality.

• Examples of metrol...read more

QA is Quality Assurance and QC is Quality Control. There are three types of QA and two types of QC.

• QA is the process of ensuring that the product meets the specified requirements and standards.

• QC is the process of ensuring that the product meets the desired quality level.

• Types of QA: Unit testing, Integration testing, System testing.

• Types of QC: Inspection, Testing.

• QA is proactive while QC is reactive.

TPM stands for Total Productive Maintenance. It is a maintenance strategy that aims to maximize equipment effectiveness and minimize downtime.

• TPM involves the entire organization, not just maintenance personnel

• The pillars of TPM are: 1) Autonomous Maintenance, 2) Planned Maintenance, 3) Quality Maintenance, 4) Training and Education, 5) Early Equipment Management

• Autonomous Maintenance involves operators taking responsibility for basic maintenance tasks

• Planned Maintenance invo...read more

Vernier and micrometer are precision measuring tools used in engineering to measure small distances accurately.

• Vernier caliper is a measuring instrument with a main scale and a sliding vernier scale for more precise measurements.

• Micrometer screw gauge is used for even more accurate measurements, typically to the nearest thousandth of an inch or hundredth of a millimeter.

• The least count of a vernier caliper is usually 0.02 mm or 0.001 inches, while the least count of a microme...read more

Types of FRCs include continuous fiber reinforced composites, discontinuous fiber reinforced composites, and hybrid composites.

• Continuous fiber reinforced composites: fibers are continuous throughout the material, providing high strength and stiffness. Example: carbon fiber reinforced polymer (CFRP).

• Discontinuous fiber reinforced composites: fibers are randomly oriented or chopped, offering improved impact resistance. Example: glass fiber reinforced polymer (GFRP).

• Hybrid comp...read more

Blocking diodes are used in junction boxes to prevent reverse current flow and protect electrical components.

• Blocking diodes are used to prevent reverse current flow in electrical circuits.

• They protect electrical components from damage caused by reverse voltage.

• Blocking diodes are commonly used in junction boxes to ensure proper current flow.

• They are also used in solar panels to prevent power loss due to reverse current.

• Examples of blocking diodes include Schottky diodes and ...read more

Quality refers to the standard or level of excellence, while quantity refers to the amount or number of something.

• Quality focuses on the characteristics, features, or attributes of a product or service.

• Quantity focuses on the size, volume, or quantity of a product or service.

• Quality is subjective and can vary based on individual preferences or requirements.

• Quantity is objective and can be measured or quantified.

• Quality is often associated with customer satisfaction and meetin...read more

Production activities refer to the processes involved in manufacturing goods or providing services.

• Production activities involve planning, designing, implementing, and monitoring the production process.

• They include activities such as procurement of raw materials, quality control, and packaging.

• Production activities are essential for ensuring that goods and services are produced efficiently and effectively.

• Examples of production activities include assembly line production, bat...read more

1:1:2 grade name refers to the ratio of ingredients in a concrete mix, where 1 part cement, 1 part sand, and 2 parts aggregate are used.

• 1:1:2 grade name is commonly used in construction and civil engineering.

• It indicates the proportion of cement, sand, and aggregate in a concrete mix.

• For example, if you need 10 kg of cement, you would also need 10 kg of sand and 20 kg of aggregate.

Maintaining productivity involves setting goals, prioritizing tasks, managing time effectively, and continuously improving processes.

• Set clear goals and prioritize tasks

• Create a schedule and stick to it

• Eliminate distractions and focus on one task at a time

• Regularly evaluate and improve processes

• Take breaks and practice self-care to avoid burnout

A 1m³ brick is a brick that has a volume of 1 cubic meter.

• A 1m³ brick is a brick that measures 1 meter in length, 1 meter in width, and 1 meter in height.

• It is a large brick with a volume of 1 cubic meter.

• The dimensions of a 1m³ brick are 1m x 1m x 1m.

• It is commonly used in construction for building large structures.

The cube size refers to the dimensions of a cube, typically measured in length, width, and height.

• The cube size can be expressed in various units such as inches, centimeters, or meters.

• For example, a cube may have dimensions of 10 inches by 10 inches by 10 inches.

• The cube size is important in determining the volume and surface area of the cube.

• It is also relevant in manufacturing and packaging processes where the cube size affects storage and transportation requirements.

There are various IS codes for different types of tests and materials used in quality engineering.

• IS 456:2000 - Code of practice for plain and reinforced concrete

• IS 3025:1983 - Methods of sampling and test (physical and chemical) for water and wastewater

• IS 1608:2005 - Mechanical testing of metals

• IS 2386:1963 - Methods of test for aggregates for concrete

• IS 10262:2009 - Guidelines for concrete mix design

• IS 13311:1992 - Methods of non-destructive testing of concrete

• IS 1077:1992 ...read more

Black box testing focuses on external behavior while white box testing focuses on internal structure.

• Black box testing is based on functional requirements and does not require knowledge of internal code.

• White box testing is based on internal code structure and requires knowledge of the code.

• Black box testing is primarily used for system-level testing.

• White box testing is primarily used for unit testing and code coverage analysis.

• Black box testing is more focused on end-user p...read more

IS 2062 is a standard for hot rolled steel used in general structural purposes.

• IS 2062 is a standard set by the Bureau of Indian Standards (BIS)

• It specifies the requirements for hot rolled steel used in general structural purposes

• The steel must have a minimum yield strength of 250 MPa

• It covers steel grades from E 250 to E 650

• IS 2062 is commonly used in the construction industry in India

To upgrade suppliers, establish clear quality standards, conduct regular audits, provide feedback and support for improvement, and consider alternative suppliers.

• Establish clear quality standards and communicate them to suppliers

• Conduct regular audits to assess supplier performance and identify areas for improvement

• Provide feedback and support to suppliers to help them meet quality standards

• Consider alternative suppliers to ensure competitiveness and continuous improvement

Quality refers to the degree of excellence or superiority of a product or service.

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

• It involves ensuring that the product or service is free from defects or errors.

• Quality also includes aspects such as reliability, durability, performance, and customer satisfaction.

• Quality can be achieved through various processes like quality control, quality assurance, and continuous improvement...read more

7 QC Tools are a set of basic statistical tools used for quality control and process improvement.

• Check sheet: Used to collect and analyze data in real time

• Histogram: Represents data distribution visually

• Pareto chart: Helps identify the most significant factors affecting a problem

• Cause-and-effect diagram: Identifies potential causes of a problem

• Scatter diagram: Shows the relationship between two variables

• Control chart: Monitors process stability over time

• Stratification: Helps ...read more

Inductance is measured in Henry (H) and is defined as the ability of a conductor to store energy in a magnetic field.

• Inductance is the property of an electrical conductor that opposes a change in current.

• It is measured in Henry (H) and is named after American scientist Joseph Henry.

• Inductance is used in various electrical components such as transformers, motors, and generators.

• The inductance of a coil can be increased by adding more turns of wire or by using a ferromagnetic c...read more

Voltage is the electric potential difference between two points. Ohm's law relates voltage, current, and resistance. NPN and PNP are types of bipolar junction transistors. Inductance formula calculates the inductance of a coil.

• Voltage is the measure of electric potential difference.

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

• NPN and PNP are types of bipolar...read more

Target mean strength is the desired strength level of a product or material.

• It is the strength level that a product or material is designed to meet or exceed.

• It is determined based on the intended use and expected stresses on the product or material.

• It is often used in quality control to ensure that products meet the desired strength level.

• For example, the target mean strength of a steel beam used in construction may be determined based on the expected load it will bear.

• The t...read more