100+ Senior Engineer Mechanical Interview Questions and Answers

Regular maintenance schedules, monitoring equipment performance, training staff on proper usage and maintenance

• Implement regular maintenance schedules for all equipment

• Monitor equipment performance and look for signs of wear or potential issues

• Train staff on proper usage and maintenance procedures to prevent breakdowns

• Keep spare parts on hand for quick repairs when needed

PEB structures are pre-engineered buildings that are fabricated off-site and then erected on-site.

• PEB structures are cost-effective and time-efficient compared to traditional construction methods.

• They are made of steel and are designed to meet specific requirements and standards.

• PEB structures are used in various industries such as warehouses, factories, and sports facilities.

• Fabrication and erection of PEB structures require skilled labor and specialized equipment.

• Quality co...read more

I follow various parameters to ensure quality and efficiency in mechanical engineering.

• I follow industry standards and regulations

• I consider safety, reliability, and durability

• I analyze and optimize designs for performance

• I use appropriate materials and manufacturing processes

• I consider environmental impact and sustainability

• I collaborate with cross-functional teams

• I continuously learn and improve my skills

Gpm for water supply pump can be calculated by dividing the flow rate in gallons by the time in minutes.

• Calculate the flow rate in gallons per minute (GPM)

• Determine the time in minutes over which the flow rate is measured

• Divide the flow rate by the time to get the GPM value

Material handling systems are used to move, store, and control materials throughout a manufacturing or distribution facility.

• Types include conveyors, cranes, hoists, automated guided vehicles (AGVs), and robotic systems.

• Conveyors are used to transport materials along a fixed path.

• Cranes and hoists are used for lifting and moving heavy materials.

• AGVs are autonomous vehicles that can transport materials without human intervention.

• Robotic systems are used for tasks such as picki...read more

I maintain a detailed logbook for each machine, including maintenance schedules, repairs, and any upgrades.

• Create a logbook for each machine

• Record maintenance schedules, repairs, and upgrades

• Include dates, details of work done, and any parts replaced

• Regularly update the logbook

• Use digital tools like spreadsheets or specialized software for easier tracking

Material science is the study of the properties and behavior of materials.

• It involves the study of the structure, properties, and performance of materials.

• It encompasses a wide range of materials including metals, ceramics, polymers, and composites.

• Material scientists use various techniques to analyze and manipulate materials, such as microscopy, spectroscopy, and mechanical testing.

• The field of material science has many practical applications, such as developing new material...read more

Oxidation process is a chemical reaction where a substance loses electrons, while bus bar calculation involves determining the size and material of bus bars for electrical distribution.

• Oxidation process involves the loss of electrons by a substance, leading to the formation of oxides.

• Bus bar calculation is the process of determining the size, material, and configuration of bus bars based on the electrical load and distribution requirements.

• Example: In oxidation process, iron ...read more

Heat exchangers are devices used to transfer heat between two or more fluids, ensuring efficient heat transfer and temperature control.

• Transfer heat between fluids

• Maintain temperature control

• Increase energy efficiency

• Commonly used in HVAC systems, refrigeration units, and chemical processing plants

Chillers are refrigeration systems used to cool water or air for air conditioning systems. TR is the unit of cooling capacity.

• Chillers use refrigeration cycles to remove heat from water or air.

• TR stands for 'ton of refrigeration' and is equal to the amount of heat required to melt one ton of ice in 24 hours.

• To find TR, calculate the heat load of the space to be cooled and divide by 12,000.

• For example, if the heat load is 240,000 BTU/hr, the TR would be 20 (240,000/12,000).

Possible reasons for a hydraulic system to get slow include fluid leaks, air in the system, worn out components, and contaminated fluid.

• Fluid leaks in the system can lead to a decrease in pressure and flow rate.

• Air trapped in the system can cause inefficiencies and reduce the system's performance.

• Worn out components such as seals, valves, or pumps can result in decreased efficiency.

• Contaminated fluid with debris or particles can clog the system and slow down the flow.

A compressor is a mechanical device that increases the pressure of a gas by reducing its volume.

• Compressors are commonly used in refrigeration, air conditioning, and gas turbines.

• They work by taking in a gas at a low pressure and volume, and then reducing the volume to increase the pressure.

• This process is achieved through the use of pistons, vanes, or rotating impellers.

• The compressed gas is then released at a higher pressure for various applications.

The code of steel used in plants is typically specified by the American Society for Testing and Materials (ASTM).

• Steel used in plants is often specified by ASTM standards.

• Common codes for steel used in plants include ASTM A36, ASTM A572, and ASTM A516.

• The specific code of steel used in a plant will depend on factors such as the type of plant, the structural requirements, and the environmental conditions.

Rider ring is a component used in reciprocating pumps to prevent leakage of fluid along the piston rod.

• Prevents leakage of fluid along the piston rod

• Helps maintain pressure within the pump

• Reduces wear and tear on the piston rod

• Commonly used in reciprocating pumps

Weld buildup and machining are done to repair or enhance the strength and durability of metal components.

• Weld buildup is used to repair worn or damaged metal parts by adding material through welding.

• Machining is then done to shape and finish the welded area to restore the part to its original dimensions.

• This process is commonly used in industries like automotive, aerospace, and manufacturing.

• It helps extend the lifespan of components and improve their performance.

• The combinat...read more

Ambition Box is a platform for job seekers to find and apply for jobs, and for employers to post job openings and search for candidates.

• Ambition Box is a job search platform

• Job seekers can find and apply for jobs

• Employers can post job openings and search for candidates

• Provides company reviews and salary information

• Offers career guidance and interview preparation tips

Equipments used in blast furnaces include stoves, hot blast valves, tuyeres, bustle pipes, and skip hoists.

• Stoves - used to preheat the air blast before it enters the furnace

• Hot blast valves - control the flow of hot air into the furnace

• Tuyeres - nozzles through which the hot air is injected into the furnace

• Bustle pipes - distribute the hot air evenly throughout the furnace

• Skip hoists - used to transport materials in and out of the furnace

I have extensive experience in designing and implementing conveying systems for various industries.

• Designed and implemented a pneumatic conveying system for a food processing plant, optimizing material flow and reducing downtime.

• Developed a conveyor belt system for a manufacturing facility, increasing production efficiency by 20%.

• Managed the installation of a bulk material handling system for a mining company, ensuring smooth operation and minimal maintenance.

• Collaborated wit...read more

Various types of welding can be used in tanks, including MIG welding, TIG welding, and submerged arc welding.

• MIG welding is commonly used for welding tanks due to its versatility and speed.

• TIG welding is often used for welding tanks that require high precision and quality welds.

• Submerged arc welding is used for welding thicker materials in tanks, providing deep penetration and high deposition rates.

I was responsible for the use and maintenance of various equipment at my last company.

• Managed regular maintenance schedules for HVAC systems, pumps, and compressors

• Performed troubleshooting and repairs on CNC machines and robotic arms

• Coordinated with vendors for calibration and servicing of precision instruments

• Trained new technicians on proper equipment operation and safety protocols

Yes, I have knowledge on Robo maintenance.

• I have experience in maintaining industrial robots such as ABB, Fanuc, and Kuka.

• I am familiar with troubleshooting and repairing mechanical, electrical, and software issues.

• I have knowledge of preventive maintenance procedures to ensure optimal performance and longevity of the robots.

• I am proficient in using diagnostic tools and software to identify and resolve issues.

• I have worked on various types of robots, including articulated, SC...read more

Pump, compressor, and turbine are all mechanical devices used to move fluids or gases.

• Pump: used to move fluids by creating pressure

• Compressor: used to increase the pressure of gases

• Turbine: used to convert the energy of a moving fluid or gas into mechanical energy

• Examples: water pump, air compressor, gas turbine

Hydraulic circuit diagram and maintenance types

• Hydraulic circuit diagram shows the flow of hydraulic fluid in a system

• Types of maintenance for hydraulic systems include preventive maintenance, predictive maintenance, and corrective maintenance

• Preventive maintenance involves regular inspections and replacements to prevent breakdowns

• Predictive maintenance uses data and analytics to predict when maintenance is needed

• Corrective maintenance involves fixing issues after they occur

• E...read more

Production adherence achievement methods involve setting clear production goals, monitoring progress, and implementing strategies to ensure targets are met.

• Set clear production goals and targets

• Monitor progress regularly

• Implement strategies to address any deviations from the plan

• Utilize production scheduling tools and software

• Train and motivate production staff to meet targets

EMS stands for Environmental Management System. ISO 14001 is a standard for implementing an EMS.

• EMS is a framework that helps organizations manage their environmental responsibilities in a systematic manner.

• ISO 14001 sets out the criteria for an environmental management system and can be certified by external bodies.

• It focuses on areas such as reducing waste, improving resource efficiency, and minimizing environmental impact.

• Implementing ISO 14001 can help organizations enhan...read more

A softener is a device used to remove minerals from water, typically calcium and magnesium, to prevent scale buildup in pipes and appliances.

• Softeners use ion exchange to replace calcium and magnesium ions with sodium ions

• The resin beads in the softener attract the calcium and magnesium ions, releasing sodium ions in exchange

• Softened water is gentler on skin, reduces soap scum, and extends the lifespan of appliances like water heaters and dishwashers

Engine function for heavy machines involves converting fuel into mechanical energy to power the machine.

• Fuel is injected into the engine's combustion chamber

• The fuel ignites and creates a controlled explosion

• The explosion pushes a piston, which turns a crankshaft

• The crankshaft converts the linear motion of the piston into rotational motion

• The rotational motion powers the machine's hydraulic system or driveshaft

• Examples of heavy machines include excavators, bulldozers, and cra...read more

The frequency of eddy current test depends on the material being tested and the thickness of the material.

• The frequency can range from a few hundred Hz to several MHz

• Higher frequencies are used for thinner materials and lower frequencies for thicker materials

• The frequency also depends on the type of probe being used

• For example, a probe with a diameter of 1mm may have a frequency of 1MHz, while a probe with a diameter of 10mm may have a frequency of 100kHz

NPI process stands for New Product Introduction process which is a set of steps taken to bring a new product to the market.

• It involves ideation, design, development, testing, and launch of the product.

• It includes market research, product definition, prototyping, and manufacturing.

• It requires collaboration between cross-functional teams such as engineering, marketing, and sales.

• It aims to ensure that the product meets customer needs, is of high quality, and is delivered on tim...read more

Hydrotest procedure involves filling the equipment with water and pressurizing it to check for leaks or structural integrity.

• Prepare the equipment by ensuring it is clean and free of debris

• Fill the equipment with water and remove air pockets

• Gradually increase the pressure to the specified level

• Hold the pressure for a specified duration to check for leaks

• Monitor for any leaks or structural failures

• Release the pressure and drain the water from the equipment

Current CTC is $90,000 and expected CTC is $110,000

• Current CTC: $90,000

• Expected CTC: $110,000

• Open to negotiation based on benefits and growth opportunities

SOP stands for Standard Operating Procedure. Lotto is a game of chance.

• SOP is a set of step-by-step instructions to carry out a specific task or operation.

• It ensures consistency and quality in the output.

• For example, a manufacturing company may have an SOP for assembling a product.

• Lotto is a game of chance where players select a set of numbers and hope to match them with the numbers drawn in a lottery.

• It is a popular form of gambling in many countries.

Eutectic point is the temperature at which a eutectic mixture solidifies or melts at a constant temperature.

• Eutectic point is the lowest possible melting point of a mixture of two or more substances.

• It is a specific composition of a mixture where the melting point is at its lowest.

• At the eutectic point, the mixture solidifies or melts at a constant temperature.

• Examples of eutectic mixtures include solder, alloys, and certain types of ceramics.

Common faults in engines and gears.

• Engine faults: overheating, low oil pressure, misfiring, knocking, stalling.

• Gear faults: slipping, grinding, difficulty shifting, noisy operation.

• Examples: worn piston rings, damaged bearings, worn synchros, damaged gears.

• Regular maintenance and inspections can prevent many faults.

• Proper lubrication and fluid levels are crucial for engine and gear health.

Safety measures are crucial during civil works to prevent accidents and injuries.

• Conducting regular safety meetings and training sessions for workers

• Providing personal protective equipment (PPE) such as hard hats, safety glasses, and gloves

• Ensuring proper use of equipment and machinery

• Implementing fall protection measures such as guardrails and safety harnesses

• Maintaining a clean and organized work area to prevent tripping hazards

• Having a designated safety officer on site to ...read more

QC is required in every industry to ensure products meet quality standards, comply with regulations, and satisfy customer expectations.

• Ensures products meet quality standards

• Helps comply with regulations and industry standards

• Ensures customer expectations are met

• Identifies and rectifies defects in products

• Improves overall product reliability and safety

Pressure classes are categories used to classify the pressure rating of piping components.

• Pressure classes are used to indicate the maximum allowable working pressure for piping components.

• Common pressure classes include 150, 300, 600, 900, 1500, and 2500.

• Each pressure class corresponds to a specific pressure rating in pounds per square inch (psi).

• Pressure classes are important for selecting the right components for a given application.

Eutectoid point is the temperature at which a eutectoid reaction occurs.

• Eutectoid point is a specific temperature at which a solid solution transforms into two or more different solid phases.

• It is a characteristic property of alloys.

• For example, the eutectoid point of steel is 727°C, at which austenite transforms into pearlite.

• Eutectoid point is important in the heat treatment of metals and alloys.

Fire protection systems include sprinkler systems, fire alarms, fire extinguishers, and smoke detectors.

• Sprinkler systems release water to suppress fires

• Fire alarms detect smoke or heat and alert occupants

• Fire extinguishers are portable devices to put out small fires

• Smoke detectors sense smoke and trigger alarms

• Other systems include fire blankets, fire doors, and fire hoses

Alignment of rotating and static equipment is crucial for smooth operation and efficiency.

• Proper alignment ensures minimal vibration and wear on components

• Use precision tools like laser alignment systems for accurate alignment

• Regularly monitor and adjust alignment to prevent issues

• Improper alignment can lead to equipment failure and costly repairs

• Examples: aligning a motor shaft with a pump shaft in a water treatment plant, aligning a gearbox with a conveyor belt in a manufac...read more

Chimney flue cane segment erection procedure involves assembling and installing individual segments of the chimney flue.

• Prepare the work area by ensuring it is clean and free of debris.

• Assemble the cane segments according to the manufacturer's instructions.

• Use appropriate tools and equipment to lift and position the segments into place.

• Secure the segments together using bolts or other fastening methods.

• Inspect the completed chimney flue for any gaps or misalignments before fi...read more

Six Sigma is a methodology used in lean manufacturing to improve processes by reducing defects and variation.

• Six Sigma aims to achieve a level of quality where there are only 3.4 defects per million opportunities.

• It focuses on identifying and eliminating causes of defects to improve overall process efficiency.

• Six Sigma uses statistical tools and techniques to measure and analyze process performance.

• It involves defining, measuring, analyzing, improving, and controlling process...read more

TPM stands for Total Productive Maintenance and JH stands for Just in Time. TPM focuses on maintaining equipment to prevent breakdowns, while JH focuses on minimizing waste and improving efficiency.

• TPM involves proactive maintenance to prevent breakdowns and improve overall equipment effectiveness

• JH focuses on reducing waste, improving efficiency, and delivering products just in time to meet customer demand

• TPM steps include setting up autonomous maintenance, planned maintenan...read more

The play of ball nut refers to the amount of axial movement allowed between the ball nut and the screw in a ball screw mechanism.

• Play of ball nut is important for ensuring smooth operation and preventing binding in the ball screw system.

• It is typically specified by the manufacturer and should be within a certain tolerance range.

• Excessive play can lead to backlash and reduced precision in the system.

• Examples of adjusting play of ball nut include tightening or loosening the pre...read more

Process gear oil replacement is the procedure of draining out old gear oil from a system and refilling it with fresh gear oil.

• Drain out old gear oil from the system

• Ensure proper disposal of the old gear oil

• Refill the system with fresh gear oil

• Follow manufacturer's guidelines for the type and amount of gear oil to be used

I handle breakdowns by staying calm, assessing the situation, troubleshooting the issue, and implementing a solution.

• Stay calm and composed to think clearly

• Assess the situation to understand the root cause

• Troubleshoot the issue systematically

• Implement a solution efficiently

• Document the breakdown and solution for future reference

Bernoulli's theorem states that as the speed of a fluid increases, its pressure decreases.

• It is a fundamental principle of fluid dynamics.

• It is based on the conservation of energy in a fluid.

• It is used to explain the behavior of fluids in pipes, nozzles, and wings.

• It is also used in the design of carburetors, airplane wings, and water turbines.