30+ Senior Engineer Manufacturing Interview Questions and Answers

The percentage of solar rays converted into energy by solar cells varies depending on the type of solar cell and environmental factors.

• The efficiency of solar cells ranges from 15% to 22% for most commercially available silicon-based solar cells.

• Newer technologies such as perovskite solar cells have achieved efficiencies of over 25% in laboratory settings.

• Environmental factors such as temperature, shading, and dust accumulation can also affect the efficiency of solar cells.

• Re...read more

A Cpk value less than 1 indicates that the manufacturing process is not capable of producing products within specifications consistently.

• A Cpk value less than 1 indicates that the process is not capable of meeting customer requirements consistently.

• It suggests that the process is not stable and may result in a high number of defects or variations.

• Improvements in the manufacturing process are needed to increase the Cpk value above 1 for better scalability.

• Examples of improveme...read more

Yes, I have experience handling entire shifts and plants independently. I would create a comprehensive training program for the 500 MP focusing on good manufacturing practices.

• Develop a training curriculum covering key manufacturing processes and best practices

• Conduct hands-on training sessions to demonstrate proper techniques

• Implement regular assessments to track progress and address any gaps in knowledge

• Provide resources such as manuals, videos, and workshops to support ong...read more

Our current manufacturing process involves assembly line production with a focus on efficiency and quality control.

• Our organisation follows a lean manufacturing process to minimize waste and maximize efficiency.

• We have recently merged the packaging and labeling process into one step to streamline production.

• Quality control checks are conducted at multiple stages to ensure product consistency and safety.

• Regular audits are performed to identify areas for improvement and optimiz...read more

To create process planning for an assembly, I would analyze the assembly process and break it down into individual steps.

• Identify the components and their specifications

• Determine the sequence of assembly steps

• Identify the tools and equipment required for each step

• Determine the time required for each step

• Create a detailed process plan document

• Continuously review and improve the process plan

There are numerous types of screws available in the market, each with its unique features and applications.

• There are over 20 types of screws commonly used in manufacturing

• Types of screws include wood screws, machine screws, sheet metal screws, and self-tapping screws

• Screws can be differentiated by their head shape, thread type, and material

• Some screws are designed for specific applications, such as drywall screws for hanging drywall or concrete screws for attaching items to c...read more

Yes, I have knowledge of document formulation and handling by QAE.

• Document formulation involves creating, editing, and organizing documents related to manufacturing processes.

• QAE (Quality Assurance Engineer) handles documents by ensuring they meet quality standards, are accurate, and are up to date.

• QAE may also be responsible for reviewing and approving documents before they are used in manufacturing.

• Examples of documents handled by QAE include work instructions, quality cont...read more

Yes, I have experience in making MSDS and HIRA. Various types of losses observed in manufacturing process include material losses, time losses, and quality losses.

• MSDS stands for Material Safety Data Sheet and HIRA stands for Hazard Identification and Risk Assessment.

• Types of losses in manufacturing process include material losses (e.g. scrap, rework), time losses (e.g. downtime, waiting), and quality losses (e.g. defects, rejects).

Yes, I have used Unigraphics CAD and CAM in my past organization. The last version I used was Unigraphics NX 12.

• Yes, I have experience using Unigraphics CAD and CAM in my previous role

• The last version I worked with was Unigraphics NX 12

• I have utilized Unigraphics for designing and manufacturing processes

I handle 3 manufacturing lines and 5 production processes.

• I handle 3 manufacturing lines

• I oversee 5 production processes

• Examples: Line 1 - Injection Molding, Line 2 - Assembly, Line 3 - Packaging

Torque value selection criteria depend on the application and the fastener being used.

• The material and size of the fastener

• The material and thickness of the joint being fastened

• The required clamping force

• The type of tool being used

• The desired level of torque accuracy

• The environmental conditions

• The torque specifications provided by the manufacturer

• The torque testing and calibration equipment available

Control plan columns include process steps, process parameters, control methods, frequency, and responsible parties.

• Process steps: list of all the steps involved in the manufacturing process

• Process parameters: variables that affect the quality of the product

• Control methods: techniques used to ensure that the process is under control

• Frequency: how often the process is monitored

• Responsible parties: individuals or teams responsible for each step of the process

Lifting tools used in assembly line include cranes, hoists, lifts, and jacks.

• Cranes are used for heavy lifting and moving large components.

• Hoists are used for lifting and moving smaller components.

• Lifts are used for raising and lowering workers to different levels.

• Jacks are used for lifting and supporting vehicles or equipment.

• Other lifting tools may include slings, chains, and hooks.

PPE in assembly line include safety glasses, gloves, earplugs, hard hats, and steel-toed shoes.

• Safety glasses to protect eyes from debris and chemicals

• Gloves to protect hands from cuts and chemicals

• Earplugs to protect ears from loud noises

• Hard hats to protect head from falling objects

• Steel-toed shoes to protect feet from heavy objects

RPN in PFMEA is calculated by multiplying Severity, Occurrence, and Detection scores.

• Assign a score of 1-10 for Severity, Occurrence, and Detection.

• Multiply the three scores to get the RPN (Risk Priority Number).

• Identify the highest RPNs and prioritize actions to reduce them.

• RPN = Severity x Occurrence x Detection.

• Use a scale to determine the score for each factor, such as the one provided by AIAG.

• Update the PFMEA with new RPNs after implementing corrective actions.

A Manufacturing Bill of Material (MBOM) is a comprehensive list of all the components, sub-assemblies, and raw materials needed to manufacture a product.

• MBOM is used to plan and manage the production process

• It includes information on the quantity, cost, and lead time of each component

• MBOM is often created using a Product Lifecycle Management (PLM) software

• It helps ensure that all necessary components are available when needed

• MBOM is an essential tool for efficient and cost-ef...read more

SOE is a documented sequence of steps or events that must occur in a specific order to complete a task or process.

• SOE is used in manufacturing to ensure consistency and quality in production.

• It outlines the specific steps and order of operations required to complete a task or process.

• SOE can be used for assembly, testing, packaging, and other manufacturing processes.

• Examples of SOE include assembly instructions for a product, a recipe for a food item, or a checklist for a mai...read more

Yes, I am capable of doing FMEA on my own.

• I have experience in conducting FMEA for various manufacturing processes.

• I am familiar with the FMEA methodology and tools.

• I can identify potential failure modes, their causes, and effects.

• I can prioritize risks and develop mitigation plans.

• I can work with cross-functional teams to implement FMEA recommendations.

Assembly sequencing involves determining the order in which parts are assembled to create a final product.

• Identify the components and their dependencies

• Determine the optimal order of assembly

• Consider factors such as safety, efficiency, and quality control

• Create a detailed assembly plan and communicate it to the team

• Continuously evaluate and improve the assembly process

Yes, I am proficient in Auto CAD.

• I have been using Auto CAD for over 5 years.

• I have experience in creating 2D and 3D models.

• I am familiar with various Auto CAD tools and commands.

• I have used Auto CAD for designing and drafting manufacturing plans.

• I am able to read and interpret Auto CAD drawings and blueprints.

Expectation and background refer to the desired outcomes and previous experience relevant to the role.

• Expectation is what the company hopes the candidate will achieve in the role

• Background is the candidate's previous experience and qualifications

• Expectation can include specific goals, targets, or responsibilities

• Background can include education, work experience, skills, and certifications

Real time machine problems can range from mechanical issues to software glitches.

• Mechanical breakdowns such as worn out parts or misalignments

• Electrical issues like faulty wiring or power supply problems

• Software glitches causing errors in operation or data processing

• Calibration errors leading to inaccurate results

• Operator error or lack of training affecting machine performance

Turning, turnmill, and milling are all machining processes used to create cylindrical or flat surfaces on a workpiece.

• Turning involves rotating a workpiece on a lathe while a cutting tool removes material to create cylindrical shapes.

• Turnmill combines turning and milling processes in one machine, allowing for complex shapes and features to be created in a single setup.

• Milling uses a rotating cutting tool to remove material from a workpiece to create flat or contoured surfaces...read more

The axes in CNC refer to the directions in which a machine can move to perform cutting or shaping operations.

• The most common axes in CNC are X, Y, and Z, representing horizontal, vertical, and depth movements respectively.

• Some machines may have additional axes such as A, B, or C for rotational movements.

• Each axis is controlled by a motor or servo drive to accurately position the cutting tool.

• The combination of movements along different axes allows for complex shapes to be mac...read more

First pass yield is the percentage of products that pass quality control on the first attempt.

• It measures the efficiency of the manufacturing process.

• It helps identify areas for improvement in the production process.

• It is calculated by dividing the number of products that pass quality control on the first attempt by the total number of products produced.

• A high first pass yield indicates a well-controlled and efficient manufacturing process.

• Example: If 100 products are produce...read more

Torque audit is a process of verifying the accuracy of torque applied to fasteners during assembly.

• It involves using a torque wrench to measure the torque applied to each fastener.

• The measured torque is compared to the specified torque in the assembly instructions.

• Any discrepancies are noted and corrected to ensure proper assembly and prevent failures.

• Torque audit is commonly used in automotive and aerospace industries.

• It is an important quality control measure to ensure prod...read more

Poke Yoke is a Japanese term for mistake-proofing. It is a technique used to prevent errors in manufacturing processes.

• Poke Yoke aims to eliminate defects by preventing human errors

• It involves designing processes and equipment to prevent mistakes from occurring

• Examples of Poke Yoke include using sensors to detect errors and prevent further processing

• Another example is using color-coding or shapes to ensure correct assembly

• Poke Yoke is an important part of Lean Manufacturing a...read more

Lean Manufacturing is a systematic method for eliminating waste within a manufacturing process to improve efficiency and quality.

• Focuses on reducing waste in all forms, including time, materials, and resources

• Involves continuous improvement and employee involvement in problem-solving

• Emphasizes value stream mapping to identify and eliminate non-value-added activities

• Utilizes tools such as 5S, Kanban, and Just-in-Time production

• Aims to increase productivity, reduce lead times, ...read more

The question is likely asking about the time it takes for a process to occur in a sideways orientation.

• Consider the efficiency and speed of processes when done sideways compared to upright

• Think about any potential challenges or benefits of sideways manufacturing

• Provide examples of sideways manufacturing processes, such as sideways drilling or cutting

Resonance is a phenomenon in which a vibrating system or external force drives another system to oscillate with greater amplitude at a specific frequency.

• Resonance occurs when the natural frequency of a system matches the frequency of an external force.

• It can lead to increased amplitudes and vibrations in the system.

• Examples include a tuning fork vibrating when struck with a mallet, or a swing being pushed at its natural frequency to increase its amplitude.