Senior Production Engineer

100+ Senior Production Engineer Interview Questions and Answers

Updated 27 Feb 2025
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Q1. What are different IS codes follow to fabricate open web girders?

Ans.

Different IS codes followed for fabricating open web girders include IS 800:2007, IS 806:1968, and IS 11384:1985.

  • IS 800:2007 - General construction in steel - Code of practice

  • IS 806:1968 - Code of practice for use of steel tubes in general building construction

  • IS 11384:1985 - Code of practice for composite construction

Q2. What are different axle capacity in open web bridges?

Ans.

Different axle capacities in open web bridges vary depending on the design and materials used.

  • Axle capacities can range from 10 tons to over 100 tons depending on the bridge design and intended use.

  • Common axle capacities for open web bridges include 20 tons, 40 tons, and 80 tons.

  • Factors such as bridge span, width, and material strength influence the axle capacity of a bridge.

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Q3. Why IATF certification required for any organization ?

Ans.

IATF certification ensures that an organization's quality management system meets international standards for automotive industry.

  • IATF certification is required for any organization that wants to supply products or services to the automotive industry.

  • It ensures that the organization's quality management system meets international standards for the automotive industry.

  • It helps to improve the organization's processes and reduce waste, defects, and errors.

  • It also helps to increa...read more

Q4. What are different types of steel bridges?

Ans.

Different types of steel bridges include truss bridges, arch bridges, suspension bridges, and cable-stayed bridges.

  • Truss bridges: made of interconnected triangles for support (e.g. Golden Gate Bridge)

  • Arch bridges: curved structure supporting weight (e.g. Sydney Harbour Bridge)

  • Suspension bridges: main cables supporting the bridge deck (e.g. Akashi Kaikyo Bridge)

  • Cable-stayed bridges: cables directly connected to the bridge deck (e.g. Millau Viaduct)

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Q5. What are different methods of blasting or cleaning of scales of raw material?

Ans.

Methods of blasting or cleaning scales of raw material include mechanical cleaning, chemical cleaning, and thermal cleaning.

  • Mechanical cleaning involves using abrasive materials like sand or steel shot to physically remove scales from the raw material surface.

  • Chemical cleaning utilizes acids or other chemicals to dissolve and remove scales from the raw material.

  • Thermal cleaning involves using heat to burn off or melt away scales from the raw material surface.

  • Other methods inc...read more

Q6. What Is PFMEA and PFD. What Is 5s What is Kaizen What is TPM What is NC handling procedure in last company.

Ans.

PFMEA stands for Process Failure Mode and Effects Analysis, PFD stands for Process Flow Diagram. 5S is a workplace organization method, Kaizen is continuous improvement, TPM is Total Productive Maintenance.

  • PFMEA is a structured approach to identifying and prioritizing potential failure modes in a process.

  • PFD is a visual representation of how a process works, showing the steps and flow of materials or information.

  • 5S is a methodology for organizing a workplace to improve effici...read more

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Q7. How you are doing line balancing and maintaining line flow

Ans.

Line balancing is done by analyzing the production process and allocating resources to ensure smooth flow.

  • Analyze production process to identify bottlenecks

  • Allocate resources to balance the workload

  • Ensure smooth flow by monitoring production metrics

  • Adjust as necessary to maintain optimal line flow

  • Use tools like time and motion studies to optimize production

Q8. What criteria should be considered when selecting appropriate welding consumables such as welding rods?

Ans.

Criteria for selecting welding consumables like welding rods

  • Consider the base metal being welded

  • Evaluate the welding process being used

  • Take into account the mechanical properties required in the final weld

  • Check for any specific industry standards or codes that need to be followed

  • Consider the environmental conditions where the welding will take place

  • Look at the cost-effectiveness of the consumables

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Q9. What is the plan for the manpower requirements needed for the fabrication of 500 MT girders, and what is the estimated duration for completing the work?

Ans.

The manpower requirements for fabricating 500 MT girders and estimated duration for completion.

  • Assess the current manpower capacity and skills within the production team

  • Calculate the number of workers needed based on the complexity of the fabrication process

  • Consider factors such as shift schedules, overtime, and potential subcontracting

  • Estimate the duration based on the daily output of the production team

  • Plan for any potential delays or unforeseen circumstances

Q10. How you introduce any new operator to line? & how you observe if there are more new joiners?

Ans.

New operator introduction and observation process

  • Introduce new operator to the team and explain their role and responsibilities

  • Provide necessary training and guidance to ensure they understand the process

  • Assign a mentor or supervisor to monitor their progress and provide feedback

  • Regularly check the attendance and schedule of the team to identify new joiners

  • Conduct a brief orientation session for new joiners to introduce them to the team and the process

Q11. How can you satisfy to the costomer. What is torque range for m5 square buts after projection welding.

Ans.

To satisfy customers, ensure quality products, timely delivery, excellent customer service, and continuous improvement. Torque range for M5 square nuts after projection welding varies based on material and application.

  • Ensure quality products by conducting thorough quality checks and inspections.

  • Deliver products on time to meet customer deadlines and expectations.

  • Provide excellent customer service by addressing any concerns or issues promptly.

  • Continuously improve processes to ...read more

Q12. What are the different types of welding and their respective methodologies?

Ans.

Different types of welding include MIG, TIG, stick, and flux-cored welding, each with its own unique methodology.

  • MIG (Metal Inert Gas) welding uses a wire electrode and a shielding gas to create a strong bond between metals.

  • TIG (Tungsten Inert Gas) welding uses a non-consumable tungsten electrode and a separate filler material to join metals.

  • Stick welding, also known as Shielded Metal Arc Welding (SMAW), uses a flux-coated electrode to create the weld.

  • Flux-cored welding uses ...read more

Q13. What is the oee, 5s, apqp,kizen, productivity control,7qc tool,lean taket time, how to control cnc production,

Ans.

OEE, 5S, APQP, Kaizen, productivity control, 7QC tool, Lean Takt Time, and CNC production control are all manufacturing concepts.

  • OEE (Overall Equipment Effectiveness) measures the efficiency of manufacturing equipment.

  • 5S is a methodology for workplace organization and standardization.

  • APQP (Advanced Product Quality Planning) is a process for ensuring quality in new product development.

  • Kaizen is a continuous improvement philosophy.

  • Productivity control involves monitoring and im...read more

Q14. If plan vs actual is 97% then what is your performance rate

Ans.

Performance rate is 97%

  • Performance rate = 100% - (100% - 97%) = 3%

  • Performance rate = 3%

  • This means the actual performance is 3% below the planned performance

Q15. Tell me about bearing manufacturing process

Ans.

Bearing manufacturing process involves several steps including forging, heat treatment, turning, grinding, and assembly.

  • Raw materials such as steel bars are forged into rough shapes of bearing rings.

  • The rings are then heat-treated to improve their strength and durability.

  • After heat treatment, the rings are turned to achieve the desired dimensions and surface finish.

  • The next step is grinding, which involves precision grinding of the bearing surfaces to ensure smooth operation....read more

Q16. How to convert high voltage to low voltage in DC supply?

Ans.

High voltage can be converted to low voltage in DC supply using a voltage regulator or a voltage divider circuit.

  • Use a voltage regulator such as a buck converter to step down the voltage

  • Implement a voltage divider circuit using resistors to reduce the voltage

  • Choose the appropriate components based on the input and output voltage requirements

  • Ensure proper heat dissipation to prevent overheating of components

Q17. What is latent heat? What is the role of LMTD in heat exchanger.

Ans.

Latent heat is the heat absorbed or released during a phase change. LMTD is used to calculate the average temperature difference in a heat exchanger.

  • Latent heat is the energy absorbed or released by a substance during a phase change without a change in temperature.

  • LMTD stands for Logarithmic Mean Temperature Difference and is used to calculate the average temperature difference between the hot and cold fluids in a heat exchanger.

  • LMTD takes into account the temperature differe...read more

Q18. Which component use to convert high voltage to low voltage in DC supply?

Ans.

A step-down transformer is used to convert high voltage to low voltage in DC supply.

  • Step-down transformer is commonly used for this purpose

  • It reduces the voltage while maintaining the same frequency

  • Examples include power adapters for electronic devices

Q19. What are the different types of welding inspections?

Ans.

Different types of welding inspections include visual inspection, radiographic testing, ultrasonic testing, magnetic particle testing, and dye penetrant testing.

  • Visual inspection involves visually examining the weld for any defects or irregularities.

  • Radiographic testing uses X-rays or gamma rays to inspect the internal structure of the weld.

  • Ultrasonic testing uses high-frequency sound waves to detect flaws within the weld.

  • Magnetic particle testing involves applying a magnetic...read more

Q20. What is Productivity and how to calculate weld length per haed and calculate wire consumption

Ans.

Productivity is the measure of output per unit of input. Weld length per head and wire consumption can be calculated using specific formulas.

  • Productivity is calculated by dividing output by input (e.g. units produced per hour of labor)

  • To calculate weld length per head, divide the total weld length by the number of heads working on the project

  • To calculate wire consumption, multiply the length of the weld by the amount of wire used per unit length

  • For example, if a project requi...read more

Q21. How many persons report you? To whom you report?

Ans.

I directly manage a team of 5 production engineers and report to the Production Manager.

  • I manage a team of 5 production engineers

  • I report to the Production Manager

  • I am responsible for overseeing production processes and ensuring efficiency

  • I provide guidance and support to my team to meet production targets

Q22. What is the main components of process equipment What are the artificial lift systems Compare between artificial lift systems The main components of beam pumping system ( surface and down hole)

Ans.

Main components of process equipment include pumps, compressors, heat exchangers, and valves. Artificial lift systems are used to increase the flow of liquids from wells. Beam pumping systems consist of surface and downhole components.

  • Main components of process equipment: pumps, compressors, heat exchangers, valves

  • Artificial lift systems: ESP (Electric Submersible Pump), PCP (Progressing Cavity Pump), Gas Lift

  • Comparison between artificial lift systems: efficiency, cost, depth...read more

Q23. Points to be considered while designing any fixture or gauge.

Ans.

Points to consider while designing fixtures or gauges.

  • Understand the purpose of the fixture or gauge

  • Consider the material and size of the workpiece

  • Ensure proper clamping and alignment

  • Design for ease of use and maintenance

  • Consider the manufacturing process and cost

  • Test and validate the fixture or gauge before use

Q24. What is different between analog and digital signals?

Ans.

Analog signals are continuous and can have infinite values, while digital signals are discrete and have a finite number of values.

  • Analog signals have a smooth waveform, while digital signals have a stepped waveform.

  • Analog signals are affected by noise and interference more than digital signals.

  • Analog signals can have an infinite number of possible values, while digital signals have a limited number of discrete values (usually 0 and 1).

Q25. What is a kaizen Ans- kaizen is a continual improvement Kai+zen = change for good,

Ans.

Kaizen is a Japanese term for continuous improvement through small incremental changes.

  • Kaizen involves everyone in the organization to identify and implement small improvements in their work processes.

  • It focuses on eliminating waste, improving quality, and increasing efficiency.

  • Kaizen is a key principle of the Toyota Production System and has been adopted by many other organizations worldwide.

  • Examples of kaizen include reducing setup times, improving communication between dep...read more

Q26. Responsibilities handled in the feild of production WRT to operators training, safety aspects, waste reduction, improved productivity, Achievements.

Ans.

As a production engineer, I have handled responsibilities such as operator training, safety measures, waste reduction, improved productivity, and achieved targets.

  • Conducted regular training sessions for operators to improve their skills and knowledge

  • Implemented safety measures to ensure a safe working environment for all employees

  • Reduced waste by implementing lean manufacturing techniques and optimizing production processes

  • Improved productivity by analyzing production data an...read more

Q27. What is different between unit Operation and unit process

Ans.

Unit operation refers to a single step in a process, while unit process involves a series of operations to achieve a specific goal.

  • Unit operation is a single step in a process, such as mixing or filtration.

  • Unit process involves a series of operations to achieve a specific goal, such as refining crude oil into gasoline.

  • Unit operations are often combined to form a unit process.

  • Unit processes are used in chemical engineering and manufacturing.

  • Understanding the difference between...read more

Q28. What are the different types of steel standards?

Ans.

Different types of steel standards include ASTM, AISI, SAE, and ISO.

  • ASTM (American Society for Testing and Materials) standards are widely used in the United States for steel specifications.

  • AISI (American Iron and Steel Institute) standards are commonly used for steel grades and compositions.

  • SAE (Society of Automotive Engineers) standards are often used for automotive steel applications.

  • ISO (International Organization for Standardization) standards provide global guidelines f...read more

Q29. How to manage if abnormal condition will happened

Ans.

To manage abnormal conditions, prioritize safety, assess the situation, take corrective actions, and communicate effectively.

  • Prioritize safety of personnel and equipment

  • Assess the situation to understand the root cause

  • Take corrective actions promptly to mitigate the abnormal condition

  • Communicate effectively with team members and stakeholders

  • Implement preventive measures to avoid recurrence

Q30. If availabilty is x then what is your performance

Ans.

Performance is dependent on various factors, not just availability.

  • Performance is influenced by factors such as skill level, experience, resources, and support.

  • Availability is just one aspect that can impact performance, but it is not the sole determinant.

  • For example, even if availability is high, performance may still be low if other factors are not optimal.

Q31. How to control breakdowns and hidden losses

Ans.

Breakdowns and hidden losses can be controlled through proper maintenance and monitoring of equipment and processes.

  • Regular maintenance and inspections can identify potential issues before they become breakdowns.

  • Implementing a preventive maintenance program can reduce the frequency of breakdowns.

  • Training employees on proper use and care of equipment can prevent damage and breakdowns.

  • Monitoring production processes can identify hidden losses, such as inefficiencies or waste.

  • An...read more

Q32. Degassing process and why it's necessary.

Ans.

Degassing is the process of removing dissolved gases from liquids to prevent defects and improve product quality.

  • Dissolved gases can cause defects in products such as bubbles or porosity.

  • Degassing is commonly used in the production of metals, plastics, and electronics.

  • Methods of degassing include vacuum degassing, sparging, and membrane degassing.

  • Degassing can also improve the shelf life and taste of food and beverages.

  • Degassing is necessary to ensure the quality and reliabil...read more

Q33. How many types of welding machines were there?

Ans.

There are several types of welding machines available for different welding processes.

  • The most common types of welding machines are MIG, TIG, Stick, and Flux-cored welders.

  • MIG welders use a wire feed and gas to create a strong bond between metals.

  • TIG welders use a tungsten electrode and filler rod to create a precise and clean weld.

  • Stick welders use a consumable electrode and are commonly used for heavy-duty welding.

  • Flux-cored welders use a wire feed and a flux core to create...read more

Q34. How to check resistance and capacitor faulty?

Ans.

Resistance and capacitor faults can be checked using a multimeter.

  • Use a multimeter to measure the resistance of a resistor. A good resistor will have a resistance value within its tolerance range.

  • For capacitors, check for any physical damage such as bulging or leaking. Use a multimeter in capacitance mode to measure the capacitance value.

  • In case of capacitors, also check for any signs of overheating or burning marks on the component.

  • For both resistance and capacitors, compare...read more

Q35. Die casting process parameters and it's calculation.

Ans.

Die casting process parameters include temperature, pressure, and cycle time.

  • Temperature: affects the fluidity of the metal and the quality of the casting.

  • Pressure: determines the filling speed and the density of the casting.

  • Cycle time: affects the productivity and the quality of the casting.

  • Calculation involves determining the optimal values for each parameter based on the specific alloy and part design.

  • Factors such as wall thickness, part geometry, and surface finish also i...read more

Q36. How will you handle rejection in online process?

Ans.

I will handle rejection in online process by analyzing the reason, learning from it, and improving my approach.

  • I will not take rejection personally and remain professional

  • I will analyze the reason for rejection and learn from it

  • I will seek feedback from colleagues or superiors to improve my approach

  • I will remain persistent and continue to apply for other opportunities

  • I will focus on my strengths and work on improving my weaknesses

Q37. How you handle conflicts?

Ans.

I handle conflicts by actively listening, understanding the root cause, and finding a mutually beneficial solution.

  • I listen to all parties involved and try to understand their perspectives

  • I identify the root cause of the conflict

  • I propose solutions that benefit all parties involved

  • I remain calm and professional throughout the process

  • I follow up to ensure the conflict has been resolved

Q38. 1. Idea of losses from any working location is improve?

Ans.

The idea is to identify and reduce losses from any working location.

  • Conduct a thorough analysis of the working location to identify potential losses

  • Implement measures to reduce losses such as improving equipment maintenance, optimizing production processes, and reducing waste

  • Regularly monitor and evaluate the effectiveness of the measures taken

  • Encourage employee involvement in identifying and addressing losses

  • Examples of losses include downtime, defects, and material waste

Q39. How to control your inhouse rework

Ans.

Implement strict quality control measures, identify root causes of rework, provide training to employees, and continuously monitor and improve processes.

  • Implement strict quality control measures to catch errors early on

  • Identify root causes of rework to address underlying issues

  • Provide training to employees to improve skills and reduce errors

  • Continuously monitor and improve processes to prevent rework

  • Utilize data analysis to identify trends and areas for improvement

Q40. How you improve your productivity rate

Ans.

I improve my productivity rate by setting clear goals, prioritizing tasks, utilizing time management techniques, and continuously seeking ways to streamline processes.

  • Setting clear goals to stay focused and motivated

  • Prioritizing tasks based on importance and deadlines

  • Utilizing time management techniques such as the Pomodoro technique or Eisenhower matrix

  • Seeking ways to streamline processes through automation or optimization

  • Regularly evaluating and adjusting my workflow for ef...read more

Q41. How you reduce change over frequency

Ans.

To reduce change over frequency, implement standardized work procedures, improve equipment reliability, optimize scheduling, and minimize setup times.

  • Implement standardized work procedures to ensure consistency and efficiency during changeovers

  • Improve equipment reliability to reduce downtime and increase productivity

  • Optimize scheduling to minimize changeover frequency and maximize production time

  • Minimize setup times by organizing tools and materials for quick and easy access

Q42. How will you calculate and improve cycle time?

Ans.

Cycle time can be calculated by dividing the total production time by the number of units produced. Improvements can be made by identifying and eliminating bottlenecks.

  • Identify bottlenecks in the production process

  • Streamline processes to eliminate unnecessary steps

  • Implement automation where possible

  • Train employees to work more efficiently

  • Regularly review and analyze production data

  • Collaborate with other departments to optimize the entire production process

Q43. Type of casting defect and it's solution.

Ans.

Shrinkage defect caused by improper cooling. Solution is to increase cooling rate or add risers.

  • Shrinkage defect occurs due to improper cooling causing the metal to shrink and leave voids in the casting.

  • Solution is to increase cooling rate or add risers to provide additional molten metal to compensate for the shrinkage.

  • Other types of casting defects include porosity, cold shuts, misruns, and hot tears.

  • Porosity is caused by trapped gas in the metal and can be prevented by usin...read more

Q44. How to convert AC to DC supply?

Ans.

AC to DC conversion involves using a rectifier to change the direction of current flow.

  • Use a rectifier to convert AC to DC by changing the direction of current flow.

  • Types of rectifiers include half-wave, full-wave, and bridge rectifiers.

  • Examples of rectifiers include diode rectifiers and semiconductor rectifiers.

Q45. What are the targets and how targets achieved

Ans.

Targets are set based on production goals and are achieved through effective planning, monitoring, and optimization of processes.

  • Targets are typically set by management based on production goals, such as increasing output or reducing costs.

  • Achieving targets involves creating detailed production plans, monitoring progress regularly, and making adjustments as needed.

  • Optimizing processes, improving efficiency, and addressing any bottlenecks are key strategies for achieving targe...read more

Q46. In your past experience have u implemented AN POKA YOKE

Ans.

Yes, I have implemented AN POKA YOKE in my past experience.

  • Implemented AN POKA YOKE to prevent errors in production processes

  • Designed foolproof mechanisms to ensure quality control

  • Trained team members on the importance and implementation of AN POKA YOKE

Q47. Disa moulding machine operation and troubleshooting

Ans.

Disa moulding machine operation and troubleshooting

  • Ensure proper sand and binder ratio

  • Check for any leaks in the hydraulic system

  • Inspect the moulding chamber for any blockages or damage

  • Monitor the temperature and humidity levels in the moulding area

  • Regularly clean and maintain the machine to prevent breakdowns

Q48. How to manage the Critical situation?

Ans.

Critical situations can be managed by staying calm, assessing the situation, and taking decisive action.

  • Stay calm and composed to avoid panic

  • Assess the situation to determine the severity and potential impact

  • Identify the root cause of the problem

  • Develop a plan of action and communicate it clearly to all involved parties

  • Take decisive action to resolve the issue as quickly and safely as possible

  • Evaluate the effectiveness of the response and make necessary adjustments

  • Document th...read more

Q49. What is role of flux in soldering?

Ans.

Flux in soldering helps to remove oxidation from the metal surfaces being joined, allowing the solder to flow more easily and create a strong bond.

  • Flux cleans the metal surfaces by removing oxides, dirt, and other contaminants.

  • It promotes wetting, which helps the solder to flow and bond properly.

  • Flux also prevents oxidation of the metal surfaces during the soldering process.

  • There are different types of flux such as rosin flux, water-soluble flux, and no-clean flux.

  • Examples of...read more

Q50. Difference between kaizen & poka yoke.

Ans.

Kaizen is continuous improvement while Poka Yoke is mistake-proofing.

  • Kaizen focuses on making small, incremental improvements to processes and systems over time.

  • Poka Yoke aims to prevent mistakes from happening by designing processes and systems in a way that makes errors impossible or easily detectable.

  • Kaizen is a long-term strategy while Poka Yoke is a short-term tactic.

  • Examples of Kaizen include implementing a suggestion box for employees to submit process improvement idea...read more

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