100+ Senior Engineer Mechanical Interview Questions and Answers

Different sheet metal manufacturing processes and their suitability based on volume, lead time, and cost.

• Laser cutting for high volume and precision

• Punching for medium volume and cost-effective production

• Waterjet cutting for low volume and complex shapes

• Bending for forming and shaping

• Stamping for high volume and repetitive shapes

• Roll forming for continuous production of long parts

• Choosing the right process based on the required tolerances, material thickness, and complexity o...read more

The questions cover various topics related to mechanical engineering, including transmission of a wheel loader, SAP PM working system, hydraulic diagram of an excavator, suspension system of a dumper, working of a Cummins engine, and common problems in truck gearboxes and differentials.

• Transmission of a wheel loader involves the transfer of power from the engine to the wheels through a series of gears and shafts.

• SAP PM is a computerized maintenance management system that help...read more

The company produces automotive components and has plants in multiple countries.

• The company specializes in manufacturing automotive components such as engines, transmissions, and chassis.

• They have plants in countries like the United States, Mexico, Germany, and China.

• The company's products are used in various vehicles including cars, trucks, and motorcycles.

Handling worsted conditions in a manufacturing job requires staying calm, problem-solving skills, and effective communication.

• Stay calm and composed under pressure to make rational decisions

• Utilize problem-solving skills to quickly address and resolve issues

• Communicate effectively with team members and supervisors to keep them informed of the situation

• Prioritize tasks based on urgency and importance to manage worsted conditions efficiently

TBM stands for Tunnel Boring Machine and CBM stands for Condition-Based Maintenance.

• TBM is a machine used to excavate tunnels by drilling through rock or soil.

• CBM is a maintenance strategy where maintenance is performed based on the condition of the equipment rather than a fixed schedule.

• Example of TBM: The Bertha TBM used to dig the SR 99 tunnel in Seattle.

• Example of CBM: Monitoring vibration levels in a rotating machine to determine when maintenance is needed.

A confined space is an area that is not designed for continuous occupancy, has limited entry and exit points, and may have poor ventilation.

• Confined spaces can include storage tanks, silos, tunnels, and sewers.

• Precautions include proper training on confined space entry procedures, use of personal protective equipment, and continuous monitoring of air quality.

• Workers should never enter a confined space alone, and a rescue plan should be in place in case of emergencies.

Condition monitoring is the process of monitoring the health of machinery and equipment to identify potential issues before they lead to failure.

• It involves using sensors to collect data on various parameters such as temperature, vibration, and noise levels.

• This data is then analyzed using algorithms to detect any anomalies or patterns that may indicate a potential problem.

• By implementing condition monitoring, maintenance can be scheduled proactively, reducing downtime and pr...read more

Work permit system is a safety procedure to control hazardous work activities and ensure proper authorization and supervision.

• Work permit system is a formal written system used to control certain types of work that are identified as potentially hazardous.

• It ensures that proper authorization is obtained before starting work, and that necessary precautions are taken to minimize risks.

• Examples of work permits include hot work permits for welding, confined space entry permits, an...read more

There were major breakdowns in the last year for Mps & vrm mill, maintenance time varied depending on the issue.

• There were 3 major breakdowns in the last year for Mps & vrm mill

• Maintenance time ranged from 2 days to 1 week depending on the issue

• Examples: gearbox failure took 3 days to repair, motor malfunction took 1 week to repair

There are two types of Vera's box: planetary and spur gear. Spur gear boxes often face problems related to noise and vibration.

• Two types of Vera's box: planetary and spur gear

• Spur gear boxes often face problems related to noise and vibration

Types of columns and reactors, and utilities such as steam boilers.

• Types of columns include packed columns, tray columns, and bubble columns.

• Types of reactors include batch reactors, continuous stirred tank reactors, and plug flow reactors.

• Utilities are systems or equipment used to support a process, such as steam boilers for generating steam.

• Steam boilers are used to generate steam for heating, power generation, and other industrial processes.

The interview questions cover topics such as grades of bolts, bearing types, types of oil and grease, iron carbon diagram, hydraulic systems, and hydraulic hose pipe nomenclature.

• HT bolt grades are determined based on the material and strength requirements, such as Grade 8.8 or Grade 10.9.

• Bearing definition: Bearings are components that support and guide moving parts, with types including ball bearings, roller bearings, and plain bearings.

• Types of oil: Engine oil, hydraulic o...read more

Implementing a visual management system to reduce waste in production processes.

• Implemented color-coded labels for different parts to reduce search time and inventory waste

• Created visual work instructions to reduce errors and rework

• Utilized kanban boards to optimize inventory levels and reduce overproduction

I have led multiple modification projects in various industries, focusing on improving efficiency and performance.

• Led a project to redesign a cooling system in a manufacturing plant, resulting in 20% energy savings

• Implemented a new material handling system in a warehouse, reducing labor costs by 15%

• Collaborated with a cross-functional team to upgrade a production line, increasing output by 25%

Different maintenance strategies include preventive maintenance, predictive maintenance, corrective maintenance, and reliability-centered maintenance.

• Preventive maintenance involves regularly scheduled inspections and maintenance to prevent breakdowns.

• Predictive maintenance uses data and analytics to predict when equipment will fail and perform maintenance before it happens.

• Corrective maintenance is done after a failure occurs to restore equipment to working condition.

• Reliabi...read more

I have extensive experience in maintaining KPIs to track performance and drive improvements.

• Developed KPIs to measure equipment reliability and maintenance efficiency.

• Regularly analyzed KPI data to identify trends and areas for improvement.

• Implemented strategies based on KPI insights to optimize maintenance processes.

• Collaborated with cross-functional teams to align KPIs with overall business goals.

Implementing preventive maintenance schedules, training staff on troubleshooting techniques, utilizing predictive maintenance technologies.

• Implementing preventive maintenance schedules to identify and address potential issues before they lead to breakdowns

• Training staff on troubleshooting techniques to quickly diagnose and resolve issues

• Utilizing predictive maintenance technologies such as vibration analysis or thermal imaging to predict when equipment may fail

• Regularly monit...read more

The number of counter weights available for a rope suspended platform varies depending on the specific design and requirements.

• The number of counter weights is determined by factors such as the weight capacity of the platform, the length of the platform, and the load distribution.

• Typically, rope suspended platforms require multiple counter weights to balance the weight of the platform and the load being lifted.

• The counter weights are usually attached to the opposite end of th...read more

Epoxy painting is commonly used on the bottom side of annular plates for corrosion protection.

• Epoxy painting is preferred for its corrosion resistance properties

• It provides a protective barrier against moisture and chemicals

• Epoxy coatings are durable and long-lasting

• Common examples of epoxy paints used for annular plates include epoxy primer and epoxy topcoat

Hydraulic systems use liquid to transmit power while pneumatic systems use gas.

• Hydraulic systems use incompressible fluid (usually oil) while pneumatic systems use compressible gas (usually air)

• Hydraulic systems can handle higher loads and pressures compared to pneumatic systems

• Pneumatic systems are generally faster in operation compared to hydraulic systems

• Hydraulic systems are more suitable for heavy-duty applications like construction equipment, while pneumatic systems are...read more

Stress strain curve shows the relationship between stress and strain in a material. Steel is stronger but less ductile than aluminum.

• Stress strain curve is a graphical representation of the behavior of a material under stress

• Steel has a higher yield strength and ultimate strength than aluminum

• Aluminum is more ductile and has a higher strain hardening capacity than steel

• Steel is more brittle than aluminum and is prone to fracture under high stress

• The modulus of elasticity of s...read more

Hydraulic systems use fluid to transmit power and are commonly used in various mechanical applications.

• Hydraulic systems use a fluid (usually oil) to transmit power.

• They consist of a hydraulic pump, valves, cylinders, and hydraulic fluid.

• Schematic diagrams show the flow of hydraulic fluid and components in the system.

• Examples of hydraulic systems include hydraulic brakes in cars and hydraulic lifts in construction equipment.

Maintenance of machineries is important to ensure their optimal performance and prevent breakdowns.

• Regular maintenance helps to identify and fix small issues before they become major problems.

• It increases the lifespan of the machinery and reduces the need for costly repairs or replacements.

• Proper maintenance also ensures the safety of workers who operate the machinery.

• Examples of maintenance tasks include lubrication, cleaning, inspection, and calibration.

• Maintenance can also...read more

A free body diagram is a visual representation of the forces acting on a body.

• It shows all the external forces acting on a body

• It helps in analyzing the forces and their effects on the body

• It is used in engineering to design and analyze structures and machines

• It is important to label all the forces and their directions in the diagram

Actuator, solenoid valve, gear type gearbox, and chain sprocket are mechanical components used in various systems.

• An actuator is a device that converts energy into motion, often used to control or move a mechanism.

• A solenoid valve is an electromechanical device that controls the flow of fluid or gas using an electric current.

• A gear type gearbox is a mechanical device that uses gears to transmit power and change the speed or torque of a rotating shaft.

• A chain sprocket is a too...read more

Electric furnaces are heating devices that use electricity to generate heat for residential or industrial purposes.

• Electric furnaces are commonly used for heating homes, offices, and industrial buildings.

• They work by converting electrical energy into heat through resistance heating elements.

• Electric furnaces are typically more energy efficient than gas furnaces, but may have higher operating costs depending on electricity rates.

• Examples of electric furnaces include electric b...read more

Hydraulic systems use fluid to transmit power and are commonly used in various applications.

• Hydraulic systems use incompressible fluid to transmit power

• They consist of a pump, reservoir, valves, cylinders, and motors

• Common applications include heavy machinery, aircraft landing gear, and brakes

• Hydraulic systems can operate at high pressures to generate significant force

• Regular maintenance is crucial to prevent leaks and ensure proper functioning

Various tools and equipment are used for alignment, such as laser alignment tools, dial indicators, alignment bars, and optical alignment systems.

• Laser alignment tools

• Dial indicators

• Alignment bars

• Optical alignment systems

To decrease expenditure cost of machinery, focus on optimizing maintenance, improving energy efficiency, and streamlining production processes.

• Implement preventive maintenance programs to reduce breakdowns and costly repairs.

• Optimize energy consumption by using energy-efficient equipment and technologies.

• Streamline production processes to minimize waste and increase productivity.

• Invest in automation and robotics to reduce labor costs and improve efficiency.

• Negotiate better de...read more

Engine oil, gear oil, axle oil, and hydraulic oil serve different purposes in a vehicle and have specific grades for optimal performance.

• Engine oil is used to lubricate internal combustion engines and comes in different grades such as 5W-30 or 10W-40.

• Gear oil is designed for transmissions, differentials, and transfer cases to reduce friction and wear. Common grades include 75W-90 or 80W-90.

• Axle oil is specifically formulated for axles to provide lubrication and cooling. Grade...read more

Ventilation is necessary in tunneling work to ensure the safety and health of workers.

• To remove harmful gases and fumes from the tunnel

• To control the temperature and humidity levels

• To provide fresh air for workers to breathe

• To prevent the buildup of dust and debris

• To maintain proper air pressure inside the tunnel

• Examples: subway tunnels, mining tunnels, road tunnels

I have worked in a pumping station with a capacity of 10,000 cubic meters per hour.

• Worked in a pumping station with a capacity of 10,000 cubic meters per hour

• Managed operations and maintenance of pumps, valves, and pipelines

• Implemented efficiency improvements to optimize pumping station performance

I have handled a wide range of machinery including CNC machines, 3D printers, industrial robots, and hydraulic systems.

• CNC machines

• 3D printers

• Industrial robots

• Hydraulic systems

Efficiency of rotary equipment can be calculated by dividing the actual output by the theoretical output.

• Efficiency = (Actual Output / Theoretical Output) x 100%

• Actual Output can be measured using instruments like flow meters, pressure gauges, etc.

• Theoretical Output can be calculated using manufacturer's data or engineering calculations.

• Efficiency can be improved by reducing friction, optimizing design, and regular maintenance.

• Example: To calculate the efficiency of a pump, m...read more

I manage vendors and subcontractors by establishing clear communication channels, setting expectations, monitoring progress, and resolving any issues promptly.

• Establish clear communication channels with vendors and subcontractors

• Set expectations regarding deliverables, timelines, and quality standards

• Monitor progress regularly to ensure project milestones are being met

• Resolve any issues or conflicts promptly to prevent delays

• Maintain positive relationships with vendors and su...read more

APQP is Advanced Product Quality Planning, a framework used in the automotive industry to ensure quality in new product development.

• APQP is a structured method for defining and establishing the steps necessary to ensure that a product satisfies the customer.

• APQP documents include FMEA (Failure Mode and Effects Analysis), Control Plan, PPAP (Production Part Approval Process), etc.

• Current company product knowledge refers to understanding the products manufactured by the company...read more

PMS stands for Piping Material Specification. One class for LPG system piping is Class 150.

• PMS is a document that specifies the materials, standards, and requirements for piping systems.

• Class 150 is a common class for LPG system piping, indicating the pressure rating of the piping components.

• PMS helps ensure that the piping system is designed and constructed according to industry standards and safety regulations.

We have a Bosch 500W drill machine at our site.

• We use a Bosch 500W drill machine for drilling holes in metal and wood.

• The drill machine has a variable speed control and a keyless chuck.

• It is lightweight and easy to handle, making it ideal for our needs.

• We also have a set of drill bits for different sizes and materials.

• The drill machine has been reliable and efficient for our projects.

Tact time is the time taken to produce one unit, while process time is the total time taken to complete a process.

• Tact time is the time taken to produce one unit of a product, while process time is the total time taken to complete the entire process.

• Tact time is usually shorter than process time as it focuses on the time taken for one unit, while process time considers all units produced.

• Correlating tact time and process time helps in identifying bottlenecks and improving ove...read more

There are three main types of defects in die casting industry: surface defects, internal defects, and dimensional defects.

• Surface defects include issues like gas porosity, shrinkage porosity, and cold shuts.

• Internal defects can be caused by trapped air, inclusions, or improper metal flow.

• Dimensional defects may result from issues with the die or improper cooling.

• Examples of defects include porosity, cracks, and misshapen parts.

Value Analysis and Value Engineering are systematic approaches to improve the value of a product or service by optimizing its functions and reducing its cost.

• Value Analysis is a process of analyzing a product or service to identify its functions and costs.

• Value Engineering is a systematic approach to improve the value of a product or service by optimizing its functions and reducing its cost.

• Value Engineering involves a team of professionals from different disciplines who work...read more

Increasing cylinder movement speed can be achieved by optimizing the design, reducing friction, increasing pressure, or using a more powerful actuator.

• Optimize the design to reduce unnecessary weight and improve efficiency

• Reduce friction by using high-quality materials, lubricants, or coatings

• Increase pressure in the system to provide more force for faster movement

• Use a more powerful actuator with higher torque or speed capabilities

• Implement advanced control systems for preci...read more

If wbt & dbt are equal, the air is fully saturated and the relative humidity is 100%.

• The air is fully saturated with water vapor.

• The relative humidity is 100%.

• Condensation may occur on surfaces due to the high moisture content in the air.

• This condition is known as the dew point temperature.

The gear module for bar rolling mills depends on various factors such as the size and weight of the bars, desired speed and torque, and the type of rolling process.

• The gear module should be selected based on the size and weight of the bars being rolled. Heavier bars may require larger gear modules to handle the increased load.

• The desired speed and torque of the rolling mill also play a role in determining the appropriate gear module. Higher speeds and torques may require smal...read more

A roots blower is a type of positive displacement pump that operates by pumping fluid between a pair of meshing lobes.

• Consists of two counter-rotating lobes that trap and move fluid through the blower

• Fluid is pushed from the inlet to the outlet without compression

• Commonly used in applications such as wastewater treatment, pneumatic conveying, and vacuum systems

A hydraulic sleeping device is a bed that can be adjusted using hydraulic mechanisms to provide comfort and support.

• Hydraulic sleeping devices often have adjustable height and angle settings for customization.

• Some models may include massage features or built-in speakers for added relaxation.

• These devices are commonly used in hospitals, nursing homes, and home care settings for patients with mobility issues.

• Examples include hospital beds with hydraulic controls for raising/low...read more

To reduce cost effectiveness of damages, focus on preventive maintenance, training, risk assessment, and using quality materials.

• Implement regular preventive maintenance schedules to identify and address potential issues before they become costly damages

• Provide training to employees on proper equipment usage and maintenance procedures to prevent accidents and damages

• Conduct regular risk assessments to identify and mitigate potential hazards that could lead to damages

• Use high-...read more