200+ Senior Quality Engineer Interview Questions and Answers

The least count of vernier caliper, micrometer, and height gauge varies based on their precision.

• Least count of vernier caliper ranges from 0.02 mm to 0.05 mm

• Least count of micrometer ranges from 0.001 mm to 0.01 mm

• Least count of height gauge ranges from 0.02 mm to 0.05 mm

• Least count is the smallest measurement that can be read on the instrument

Control plan is a documented procedure to ensure consistent quality of a product or service.

• Identify critical process steps and potential failure modes

• Develop controls to prevent or detect failures

• Assign responsibility for each control

• Establish monitoring and response plans

• Review and update the control plan regularly

Interview questions for Senior Quality Engineer position

• findElements returns a list of web elements while findElement returns a single web element

• OOPS concepts include inheritance, polymorphism, encapsulation, and abstraction

• TestNG framework allows for easy test case management and reporting

• Reports in TestNG can be generated using the TestNG XML file or by using listeners

• Defect life cycle includes identification, logging, prioritization, fixing, and verification

• Priority and s...read more

PPAP stands for Production Part Approval Process. It is a standardized process used in the automotive industry to ensure that suppliers meet quality requirements.

• PPAP is a set of guidelines and requirements that suppliers must follow to demonstrate their ability to consistently produce parts that meet customer specifications.

• It involves submitting documentation and samples to the customer for approval before production begins.

• The documentation includes items such as control p...read more

QA/QC stands for Quality Assurance/Quality Control. It involves testing and inspection of materials and products to ensure they meet quality standards.

• QA/QC is a process of ensuring quality in products and materials

• It involves testing and inspection of materials and products

• Concrete, cement, aggregates, TMT bars, and soil are some of the materials that require QA/QC

• Knowledge of chemical and physical properties of these materials is necessary

• Mix design of concrete as per IS Co...read more

Accuracy refers to how close a measured value is to the true value, while precision refers to how close multiple measurements are to each other.

• Accuracy is the degree of closeness between a measured value and the true value.

• Precision is the degree of closeness between multiple measurements of the same quantity.

• Accuracy is related to systematic errors, while precision is related to random errors.

• Accuracy can be affected by bias, while precision can be affected by variability.

• A...read more

These are quality control methodologies used in manufacturing processes.

• 8D is an eight-step problem-solving process used to identify, correct, and prevent problems

• FMEA is a risk assessment tool used to identify and prioritize potential failures in a process

• PPAP is a process used to ensure that suppliers have met all customer requirements before production begins

• SPC is a statistical process control method used to monitor and control a process

• MSA is a measurement system analysi...read more

Snagging is the process of identifying and rectifying defects or issues in a construction project before completion.

• Inspecting the construction site for any defects or issues

• Checking for quality of materials used

• Ensuring compliance with building codes and regulations

• Creating a snagging report detailing all identified issues

• Coordinating with contractors to address and rectify the snagged items

Yes, I have experience in ISO standards, 5S, and Kaizen.

• I have worked with ISO 9001 and ISO 13485 standards in my previous roles.

• I have implemented 5S methodology in a manufacturing plant, resulting in improved efficiency and reduced waste.

• I have led Kaizen events to identify and eliminate process inefficiencies.

• Overall, I have 5 years of experience in these areas.

To verify the accuracy of CMM readings, I would use calibration standards, conduct repeatability tests, and compare results with known measurements.

• Use calibration standards to verify the accuracy of CMM readings.

• Conduct repeatability tests to ensure consistent results.

• Compare CMM measurements with known measurements to validate accuracy.

Use straight edge and feeler gauge to check flatness of the table.

• Use a straight edge to check for any gaps between the table surface and the straight edge.

• Use a feeler gauge to measure any deviations from flatness at various points on the table.

• Repeat the process in multiple directions to ensure overall flatness of the table.

• Document the measurements and compare them against the acceptable flatness tolerance for the table.

Yes, it is possible to check the flatness of a big round conference table.

• Use a straight edge or level to check for any deviations from flatness

• Measure the distance between the table surface and the straight edge at multiple points

• Look for any gaps or unevenness in the measurements

• Consider using a laser level for more accurate results

I am using the Datum Reference Frame alignment method to align the job on CMM.

• Datum Reference Frame alignment method is commonly used in CMM to establish a coordinate system based on specific datums on the part.

• This method involves selecting primary, secondary, and tertiary datums to align the part in the correct orientation.

• The alignment process ensures accurate measurement and inspection of the part's features.

• Examples of datums include flat surfaces, holes, or edges that a...read more

Using precision measuring tools like calipers, levels, and squares to check parallelity & perpendicularity of conference table.

• Use a precision level to check if the table surface is parallel to the ground

• Measure the distance between opposite corners to ensure the table is square

• Use a square tool to check the right angles of the table

• Calipers can be used to measure the thickness of the table legs for uniformity

A requirement is a need or expectation from a stakeholder. A requirement traceability matrix is a tool to track requirements throughout the project lifecycle.

• Requirement is a statement that specifies what a product or service should do or how it should perform.

• Requirement Traceability Matrix (RTM) is a document that links requirements to their origin and traces them throughout the project lifecycle.

• RTM helps to ensure that all requirements are met and that changes to requirem...read more

Surface finish refers to the texture or smoothness of a surface after it has been machined or treated.

• Surface finish is measured in units such as Ra (roughness average) or Rz (average maximum profile height).

• A smooth surface finish is important for reducing friction, improving aesthetics, and ensuring proper functionality.

• Common methods for achieving desired surface finishes include grinding, polishing, and coating.

• Surface finish can impact the performance and longevity of a ...read more

Yes, surface finish can have further types or subtypes such as roughness, waviness, and lay.

• Surface roughness refers to the finely spaced irregularities on the surface of an object.

• Surface waviness refers to the more widely spaced deviations of the surface from a straight line.

• Surface lay refers to the direction of the predominant surface pattern.

I have experience in various types of testing including functional, regression, performance, and security testing.

• Functional testing to ensure the product meets the specified requirements

• Regression testing to ensure new changes do not affect existing functionality

• Performance testing to ensure the product can handle expected load and response times

• Security testing to identify and mitigate potential vulnerabilities

• Testcases in helmet for impact resistance, durability, and comfo...read more

I have a strong engineering drawing reading and understanding level.

• I have extensive experience in interpreting complex engineering drawings and schematics.

• I am proficient in understanding geometric dimensioning and tolerancing (GD&T) symbols.

• I have successfully collaborated with design teams to ensure accurate interpretation of drawings.

• I have a keen eye for detail and can identify potential issues or discrepancies in drawings.

• I am familiar with industry standards and best p...read more

I have experience using a Zeiss CMM machine with Calypso software.

• Used Zeiss CMM machine for precision measurements

• Proficient in operating Calypso software for data analysis

• Performed dimensional inspections using CMM technology

Initial setting time and Final setting time of Cement refers to the time taken for the cement to change from a liquid to a solid state.

• Initial setting time is the time taken for the cement paste to lose its plasticity and become rigid enough to resist certain defined pressure.

• Final setting time is the time taken for the cement paste to completely harden and attain its full strength.

• The setting time of cement is influenced by factors such as the type of cement, water-cement ra...read more

Types of tests conducted before, during, and after work at a site include pre-construction testing, in-process testing, and post-construction testing.

• Pre-construction testing: soil testing, environmental impact assessments

• In-process testing: quality control checks, material testing

• Post-construction testing: structural integrity testing, final inspection

I will use a precision alignment tool such as a laser level or optical alignment system to align the job as per the presented drawing.

• Use a laser level to ensure the job is aligned horizontally and vertically according to the drawing

• Utilize an optical alignment system to align specific features or components as per the drawing

• Check for any discrepancies between the job and the drawing and make necessary adjustments

To handle dropdown in Selenium, we can use the Select class and its methods like selectByVisibleText, selectByValue, and selectByIndex.

• Create an instance of the Select class by passing the dropdown element as a parameter

• Use selectByVisibleText method to select an option by its visible text

• Use selectByValue method to select an option by its value attribute

• Use selectByIndex method to select an option by its index

• To deselect an option, use deselectAll or deselectBy methods

Durability testing of alloy wheels involves subjecting them to various stressors to assess their strength and performance.

• Conducting fatigue tests to simulate real-world conditions

• Applying load and pressure to assess the wheel's ability to withstand stress

• Testing for impact resistance by dropping weights on the wheels

• Examining the wheels for cracks, deformations, or other signs of damage

• Analyzing the results to determine the wheel's durability and potential improvements

Paint test of aluminium alloy wheels is ensured through a combination of visual inspection, adhesion testing, and corrosion resistance testing.

• Visual inspection is conducted to ensure that the paint is evenly applied and free from defects such as bubbles, cracks, or peeling.

• Adhesion testing is performed to ensure that the paint adheres properly to the surface of the wheel and does not flake off easily.

• Corrosion resistance testing is conducted to ensure that the paint provides...read more

Yes, there are subtypes for the types of GD&T parameters.

• Profile of a surface for flatness, straightness, circularity, etc.

• Position for concentricity, symmetry, etc.

• Runout for circular runout, total runout, etc.

Polymers are large molecules composed of repeating structural units, and there are several types of rubber used in the sealing industry.

• Polymers are large molecules made up of repeating units called monomers.

• Rubber is a type of polymer that can be natural or synthetic.

• Common types of rubber used in the sealing industry include neoprene, EPDM, silicone, and nitrile rubber.

Defect is a deviation from expected behavior. Defect Life Cycle is the process of identifying, reporting, and resolving defects.

• Defect is a flaw or error in a product or service that deviates from its expected behavior.

• Defect Life Cycle includes identifying, reporting, prioritizing, fixing, and verifying defects.

• Defects can be found during testing, development, or even after release.

• Defects can be classified based on severity, priority, and type.

• Examples of defects include cr...read more

My current KRA is to improve product quality by implementing effective quality control measures. Achievements include reducing defect rate by 20% and increasing customer satisfaction by 15%.

• Implemented statistical process control to identify and address quality issues

• Conducted root cause analysis to identify the source of defects and implemented corrective actions

• Collaborated with cross-functional teams to improve product design and manufacturing processes

• Conducted regular au...read more

7QC tools are used for quality control and problem-solving. Example: Pareto chart for identifying the most frequent defects.

• Check sheet for collecting data

• Pareto chart for identifying the most frequent defects

• Cause-and-effect diagram for identifying root causes

• Histogram for analyzing data distribution

• Scatter diagram for identifying relationships between variables

• Control chart for monitoring process performance

• Flowchart for visualizing process flow

ISO 9001 has 10 clauses, internal audit program has 6 clauses, and planning has no specific number of clauses.

• ISO 9001 has clauses related to context of the organization, leadership, planning, support, operation, performance evaluation, and improvement

• Internal audit program has clauses related to audit planning, audit preparation, audit execution, audit reporting, audit follow-up, and audit records

• Planning does not have a specific number of clauses as it can vary depending on...read more

PPAP documents have 5 levels: Level 1, Level 2, Level 3, Level 4, and Level 5.

• Level 1: Part Submission Warrant (PSW)

• Level 2: Part Submission Status

• Level 3: Part Submission Initial Sample Inspection Report (ISIR)

• Level 4: Part Submission Performance Test Results

• Level 5: Part Submission Bulk Material Test Results

Yes, sheet metal parts often require fixtures to hold them in place during manufacturing processes.

• Sheet metal parts often have complex shapes that require fixtures to ensure accurate and consistent manufacturing.

• Fixtures can be custom-designed to hold the sheet metal parts securely in place during processes such as cutting, bending, and welding.

• Common types of fixtures for sheet metal parts include clamps, jigs, and specialized tooling.

• Using fixtures helps to improve the qua...read more

Test cases for Prime customers in Amazon Big Billion Day

• Verify that Prime customers have access to exclusive deals and discounts

• Check if Prime customers receive faster shipping options compared to non-Prime customers

• Ensure that Prime customers are able to access Prime Day deals and promotions

• Confirm that Prime customers receive special perks such as early access to deals

Standard deviation is a measure of the amount of variation or dispersion of a set of values.

• Standard deviation is calculated by taking the square root of the variance.

• It is used to quantify the amount of variation or dispersion of a set of values.

• Higher standard deviation indicates more spread out data points, while lower standard deviation indicates data points are closer to the mean.

• It is commonly used in quality control to monitor the consistency of processes and products....read more

Customer quality refers to meeting or exceeding customer expectations. To solve customer problems, it is important to listen, empathize, and take action.

• Listen actively to the customer's concerns and ask clarifying questions

• Empathize with the customer and acknowledge their frustration

• Take ownership of the problem and provide a clear plan of action to resolve it

• Follow up with the customer to ensure their satisfaction

• Continuously gather feedback from customers to improve the ov...read more

Inherited variables and methods can be overridden in child classes.

• Inheritance allows child classes to access parent class variables and methods.

• Child classes can override inherited variables and methods with their own implementation.

• The 'super' keyword can be used to call the parent class version of an overridden method.

• Example: class Child extends Parent { int variable = 5; void method() { super.method(); } }

Precautions for slab concrete in rainy season

• Ensure proper drainage to prevent water accumulation on the slab

• Cover the slab with waterproof materials to protect it from rain

• Monitor weather forecasts and plan concrete pouring accordingly

• Use additives in the concrete mix to improve its resistance to water damage

• Allow extra time for curing due to slower drying in rainy conditions

These are essential tools for a Senior Quality Engineer to ensure quality control and continuous improvement.

• Why-Why analysis helps to identify the root cause of a problem and develop effective solutions.

• Problem-solving techniques like DMAIC, PDCA, and 8D are used to systematically solve problems and improve processes.

• MSA (Measurement System Analysis) is used to evaluate the measurement system's accuracy, precision, and stability.

• SPC (Statistical Process Control) is used to m...read more

Carbon fibre wrapping is a technique used to reinforce structures using carbon fibre sheets and epoxy resin.

• Carbon fibre wrapping involves applying carbon fibre sheets to a surface using epoxy resin.

• The surface to be wrapped should be cleaned and prepared before applying the carbon fibre sheets.

• The carbon fibre sheets are cut to the desired size and shape, and then laid onto the surface.

• Epoxy resin is applied to the carbon fibre sheets, saturating them and bonding them to the...read more

FMEA, control plan, and 7QC tools are essential for ensuring quality in customer handling processes.

• FMEA (Failure Mode and Effects Analysis) helps identify potential failure modes in customer handling processes and prioritize actions to mitigate risks.

• Control plan outlines the steps to ensure that customer handling processes are consistently meeting quality standards.

• 7QC tools (such as Pareto analysis, cause and effect diagram, and control charts) can be used to monitor and i...read more

Process Quality refers to the overall quality of a process, while Layer Audits are specific checks performed at different stages of the process.

• Process Quality is a measure of the effectiveness and efficiency of a process as a whole

• Layer Audits are specific checks performed at different stages of the process to ensure quality

• Process Quality is focused on improving the overall process, while Layer Audits are focused on identifying and correcting specific issues

• Process Quality ...read more

Standard procedures for UT, tensile and impact testing

• UT testing follows ASTM E164 standards

• Tensile testing follows ASTM E8 standards

• Impact testing follows ASTM E23 standards

• Work instructions should include equipment calibration, sample preparation, and testing procedures

• Documentation of results and analysis should be included in the work instructions

Scrap reductions can be achieved through process improvements and defect prevention.

• Identify root causes of scrap and implement corrective actions

• Implement statistical process control to monitor and improve process performance

• Train employees on proper handling and use of materials and equipment

• Implement quality checks at various stages of production

• Collaborate with suppliers to improve material quality

• Invest in new technology or equipment to improve efficiency and reduce wast...read more

Maintaining and standardizing salt spray pH is crucial for accurate testing results.

• Regularly calibrate the pH meter to ensure accuracy

• Use a buffer solution to verify the pH meter readings

• Maintain the salt spray solution at a consistent pH level

• Follow industry standards and guidelines for salt spray testing

• Document all procedures and results for quality control purposes

Yes, GD&T parameters refer to the geometric dimensioning and tolerancing standards used to define the allowable variations in a part's geometry.

• GD&T parameters include symbols such as flatness, parallelism, perpendicularity, concentricity, and position.

• These parameters help ensure that parts are manufactured and inspected accurately to meet design requirements.

• For example, a flatness tolerance specifies the allowable deviation from a perfectly flat surface.

• Understanding GD&T ...read more