Senior NPD Engineer
20+ Senior NPD Engineer Interview Questions and Answers
Q1. What is Control plan and types of control plan.
Control plan is a document that outlines the steps to be taken to ensure quality control during manufacturing.
It includes details on the process, inspection methods, and frequency of checks.
Types of control plans include Prototype, Pre-Launch, Production, and After-Launch.
Prototype control plans are used during the development phase, while Pre-Launch control plans are used before mass production.
Production control plans are used during mass production, and After-Launch contro...read more
Q2. What is PPAP , and how many documents in It.
PPAP stands for Production Part Approval Process. It is a standardized process in the automotive industry to ensure product quality.
PPAP is a set of documents and procedures used to demonstrate that a product meets customer requirements.
It includes documents such as control plans, design records, process flow diagrams, and measurement system analysis.
PPAP is typically required for new product introductions or when changes are made to existing products.
The number of documents ...read more
Senior NPD Engineer Interview Questions and Answers for Freshers
Q3. What is APQP? and how many phase of APQP ?
APQP stands for Advanced Product Quality Planning. It is a structured approach to product development.
APQP is a process used in the automotive industry to ensure that new products meet customer requirements and are launched on time and within budget.
There are five phases of APQP: Planning and Program Definition, Product Design and Development, Process Design and Development, Product and Process Validation, and Launch, Feedback, Assessment and Corrective Action.
APQP involves c...read more
Q4. What is the procedure to execute the New Product Development
The procedure for executing New Product Development involves several stages from ideation to launch.
Ideation and concept development
Market research and analysis
Design and engineering
Prototyping and testing
Manufacturing and production
Marketing and launch
Continuous improvement and feedback
Cross-functional collaboration and communication
Q5. What is Process capability index?
Process capability index is a statistical measure of a process's ability to produce consistent results within specification limits.
Process capability index is used to evaluate the ability of a process to meet customer requirements.
It is calculated by dividing the specification width by the process width.
A process capability index of 1 indicates that the process is capable of producing within the specification limits.
A process capability index of less than 1 indicates that the...read more
Q6. What is PFMEA and how execute this?
PFMEA stands for Process Failure Mode and Effects Analysis. It is a structured approach to identify and mitigate potential failures in a process.
PFMEA is a proactive risk assessment tool used during the design or modification of a process.
It involves identifying potential failure modes, their effects, and the likelihood of occurrence.
The identified risks are then prioritized based on their severity and likelihood of occurrence.
Actions are then taken to mitigate the highest pr...read more
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Q7. What is Process Capability?
Process Capability is the ability of a process to consistently produce products within specification limits.
It is a statistical measure of the ability of a process to produce output within specification limits
It is calculated using the process capability index (Cpk) which compares the process variability to the specification limits
A process with a Cpk value of 1 or higher is considered capable
Process Capability is important in ensuring quality and reducing defects in manufact...read more
Q8. What is the Press tool construction & explain
Press tool construction refers to the design and fabrication of tools used in press machines for shaping or forming materials.
Press tool construction involves designing and manufacturing tools used in press machines.
These tools are used to shape or form materials through processes like cutting, bending, or punching.
Press tools are typically made from high-strength materials like steel to withstand the forces involved.
The construction of press tools includes various components...read more
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Q9. How to calculate cutting speed in vmc machine
Cutting speed in VMC machine can be calculated using the formula: Cutting speed (m/min) = (pi * diameter * RPM) / 1000
Calculate the diameter of the cutting tool
Determine the RPM of the spindle
Use the formula: Cutting speed (m/min) = (pi * diameter * RPM) / 1000
For example, if the diameter of the cutting tool is 10mm and the spindle RPM is 1000, the cutting speed would be (3.14 * 10 * 1000) / 1000 = 31.4 m/min
Q10. Do you know excel conditioning?
Yes, I am familiar with Excel conditioning.
Excel conditioning involves using formulas and functions to manipulate data in Excel.
Examples include using IF statements, VLOOKUP, and conditional formatting.
I have experience using Excel conditioning to analyze and manipulate data for NPD projects.
Q11. What is APQP? Explain different stages.
APQP stands for Advanced Product Quality Planning. It is a framework used in the automotive industry to ensure quality in product development.
APQP is a structured process that helps organizations plan and develop new products or make changes to existing products.
The stages of APQP include planning and defining the program, product design and development, process design and development, product and process validation, and product launch.
During the planning stage, the team defi...read more
Q12. What is control Plan and SOP
Control Plan is a document that outlines the steps to be taken to ensure quality standards are met. SOP is a set of instructions for a specific task.
Control Plan is a proactive approach to quality control
It identifies potential issues and outlines steps to prevent them
SOP is a step-by-step guide for performing a specific task
It ensures consistency and efficiency in operations
Both are important tools for ensuring quality and consistency in manufacturing processes
Q13. What are the documents required for PPAP
PPAP (Production Part Approval Process) requires several documents for submission.
Part Submission Warrant (PSW)
Design Records
Engineering Change Documents
Process Flow Diagram
Process Failure Mode and Effects Analysis (PFMEA)
Control Plan
Measurement System Analysis (MSA)
Dimensional Results
Material Performance Test Results
Initial Process Studies
Qualified Laboratory Documentation
Appearance Approval Report (AAR)
Sample Production Parts
Q14. How does a turbocharger work
A turbocharger uses exhaust gases to spin a turbine, which compresses air and forces it into the engine for increased power.
Exhaust gases flow through the turbine, causing it to spin at high speeds
The turbine is connected to a compressor, which compresses air and forces it into the engine
This compressed air allows for more fuel to be burned, resulting in increased power and efficiency
Turbochargers are commonly used in high-performance cars and diesel engines
Q15. Software known and modules that you know
I have experience with various software known and modules.
Proficient in CAD software such as AutoCAD and SolidWorks
Familiar with simulation software like ANSYS and COMSOL
Knowledge of programming languages like C++, Python, and MATLAB
Experience with project management tools such as JIRA and Trello
Understanding of version control systems like Git and SVN
Q16. Plastic sheet metal casting design
Plastic sheet metal casting design
Consider the material properties of plastic and sheet metal
Design the casting to accommodate the shrinkage of plastic
Ensure proper gating and venting for the casting process
Consider the draft angles and undercuts for easy demolding
Optimize the design for strength and structural integrity
Q17. What about mould design
Mould design is crucial in NPD engineering for ensuring product quality and manufacturability.
Mould design impacts product quality, cost, and time-to-market
Consider factors like material selection, part geometry, cooling system, and ejection method
Use CAD software for designing and simulation to optimize mould design
Collaborate with tooling suppliers for expertise in mould design
Iterate and test mould designs to ensure manufacturability and quality
Q18. How to select vmc toling
Selecting VMC tooling involves considering factors like material, tool geometry, cutting parameters, and tool life.
Consider the material being machined and choose a tool material that is suitable for it
Select the appropriate tool geometry based on the desired surface finish and chip control
Optimize cutting parameters such as speed, feed rate, and depth of cut for efficient machining
Evaluate tool life and choose a tool that can withstand the required number of cuts
Consider the...read more
Q19. Salery structure explains
Salary structure refers to the way an organization determines and defines employee compensation.
Salary structure includes base pay, bonuses, benefits, and other forms of compensation.
It is important for an organization to have a clear and fair salary structure to attract and retain top talent.
Salary structure can vary by industry, job function, and geographic location.
For example, a software engineer in San Francisco may have a different salary structure than a software engin...read more
Q20. Components of screw compressor pacakge
The components of a screw compressor package include the compressor unit, motor, control panel, cooling system, and piping.
Compressor unit: The main component that compresses the air or gas.
Motor: Provides the power to drive the compressor unit.
Control panel: Allows for monitoring and controlling the compressor operation.
Cooling system: Keeps the compressor and motor at optimal operating temperatures.
Piping: Connects the compressor unit to the rest of the system for air or ga...read more
Q21. Latest trends in auto industry
Electric vehicles, autonomous driving, connectivity, and sustainability are the latest trends in the auto industry.
Electric vehicles are becoming more popular due to environmental concerns and government regulations.
Autonomous driving technology is advancing rapidly, with companies like Tesla and Waymo leading the way.
Connectivity features such as in-car Wi-Fi and advanced infotainment systems are becoming standard in new vehicles.
Sustainability is a key focus, with automaker...read more
Q22. What is 6 Sigma
6 Sigma is a set of techniques and tools for process improvement, aiming to reduce defects and variation in manufacturing and business processes.
6 Sigma focuses on identifying and removing causes of defects and errors in processes
It uses statistical analysis to measure and improve process performance
The goal of 6 Sigma is to achieve a level of quality where there are only 3.4 defects per million opportunities
Companies like Motorola and General Electric have successfully imple...read more
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