100+ Senior Production Engineer Interview Questions and Answers

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

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.

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

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)

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

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

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

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

Performance rate is 97%

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

• Performance rate = 3%

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

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

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

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

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

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

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

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

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).

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

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

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

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

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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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.

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

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

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

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

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

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

The OEE of the plant is 85%.

• OEE stands for Overall Equipment Effectiveness.

• It is a measure of how well a manufacturing process is performing.

• It takes into account three factors: availability, performance, and quality.

• An OEE of 85% is considered to be a good score.

• It means that the plant is operating efficiently and effectively.

Approximately 100 tons of material is consumed in one month.

• The material type and source should be identified.

• The consumption rate should be monitored regularly.

• Efforts should be made to reduce material waste.

• The cost of material consumption should be analyzed.

Listen to the complaint, empathize with the customer, investigate the issue, offer a solution, follow up to ensure satisfaction.

• Listen actively to the customer's complaint without interrupting

• Empathize with the customer and acknowledge their frustration

• Investigate the issue to understand the root cause

• Offer a solution that addresses the customer's concerns

• Follow up with the customer to ensure their satisfaction with the resolution

Shrinkage defect is a common casting defect caused by the solidification of metal.

• Shrinkage defect occurs when the metal solidifies and shrinks before filling the entire mold cavity.

• It can be prevented by increasing the pouring temperature, using risers, and modifying the mold design.

• Proper gating and venting can also help prevent shrinkage defects.

• Examples of shrinkage defects include shrinkage porosity and shrinkage cavity.

I use a variety of metrics to track production efficiency and quality.

• I use metrics such as OEE (Overall Equipment Efficiency), cycle time, downtime, scrap rate, and yield.

• These metrics help me identify areas for improvement and track the success of implemented changes.

• For example, I may use OEE to measure the overall effectiveness of a production line, while cycle time helps me understand the time it takes to complete a specific task.