200+ Senior Quality Engineer Interview Questions and Answers

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

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

Yes, the 5S terms in Japanese are Seiri, Seiton, Seiso, Seiketsu, and Shitsuke.

• Seiri - Sort (整理)

• Seiton - Set in Order (整頓)

• Seiso - Shine (清掃)

• Seiketsu - Standardize (清潔)

• Shitsuke - Sustain (躾)

GD&T parameters include form, profile, orientation, location, and runout.

• Form controls the shape of the part

• Profile controls the outline of the part

• Orientation controls the angle of features

• Location controls the position of features

• Runout controls the circularity of features

Scenarios to test movie ticket booking app include user registration, movie selection, seat selection, payment processing, and booking confirmation.

• User registration process

• Movie selection and availability

• Seat selection and seating arrangement

• Payment processing and options

• Booking confirmation and ticket generation

SPC stands for Statistical Process Control. It is a method of quality control that uses statistical methods to monitor and control a process.

• SPC helps in identifying and reducing variation in a process, leading to improved quality and consistency of products or services.

• It involves collecting and analyzing data to understand the performance of a process over time.

• If SPC is not implemented, there is a higher risk of producing defective products, increased costs due to rework o...read more

The strength of the cover block should be sufficient to withstand the load and provide adequate support to the reinforcement bars.

• The strength of the cover block is typically specified in terms of its compressive strength, which should be at least 20 MPa.

• The cover block should be able to resist any potential impact or external forces without breaking or deforming.

• The dimensions of the cover block should be appropriate for the size and spacing of the reinforcement bars.

• Proper ...read more

A tyre is a rubber covering on a wheel to provide traction and cushioning. There are various types of tyre testing to ensure quality and performance.

• Types of tyre testing include tread wear testing, wet traction testing, rolling resistance testing, and high-speed testing.

• Other types of testing may include endurance testing, noise testing, and uniformity testing.

• Testing methods can vary based on the type of tyre (e.g. passenger car, truck, motorcycle) and intended use (e.g. ra...read more

If HRA not provided for family, negotiate for additional compensation.

• Negotiate for additional compensation to cover the cost of housing for family

• Research the cost of housing in the area and present this information during negotiations

• Consider alternative options such as company-provided housing or a housing allowance

• Ensure that any agreement reached is clearly outlined in the employment contract

Cp and Cpk are process capability indices used to measure how well a process is performing within specification limits.

• Cp measures how well the process spread fits within the specification limits

• Cpk measures how centered the process is between the specification limits

• Cp and Cpk are calculated using the formula: Cp = (USL - LSL) / (6 * standard deviation) and Cpk = min((USL - mean) / (3 * standard deviation), (mean - LSL) / (3 * standard deviation))

• A Cp value of 1 indicates th...read more

Rework material should be segregated and evaluated for usability or disposal based on its quality and safety.

• Segregate rework material based on its quality and safety.

• Evaluate the usability of rework material.

• Dispose of rework material if it cannot be used safely or effectively.

• Consider recycling or repurposing rework material if possible.

• Document the disposal or use of rework material for quality control purposes.

You can read data from Excel using Selenium by using Apache POI library.

• Use Apache POI library to interact with Excel files in Selenium

• Create a FileInputStream object to read the Excel file

• Use WorkbookFactory to create a workbook object from the FileInputStream

• Get the desired sheet from the workbook using getSheet() method

• Iterate through rows and cells to read data from Excel sheet

MSA Criteria refers to Measurement System Analysis criteria used to evaluate the performance of a measurement system.

• MSA Criteria includes Accuracy, Precision, Repeatability, Reproducibility, Linearity, and Stability.

• Accuracy refers to how close the measured values are to the true values.

• Precision refers to the consistency of repeated measurements.

• Repeatability is the variation in measurements taken by a single operator using the same equipment.

• Reproducibility is the variatio...read more

The list count of micrometer depends on the type and model of the micrometer.

• The list count of micrometer refers to the number of divisions on the thimble or sleeve of the micrometer.

• Different types and models of micrometers have different list counts.

• For example, a standard outside micrometer typically has a list count of 40, while a digital micrometer may have a list count of 0.001mm.

• The list count is important for determining the precision and accuracy of the micrometer.

• It...read more

Problem solving tools for Senior Quality Engineer

• 8D is a structured problem-solving approach

• 7QC tools include Pareto charts, fishbone diagrams, etc.

• Why Why analysis helps to identify root cause

• QMS core tools include FMEA, Control Plan, etc.

• ISO 9001:2015 is a quality management standard

• Process knowledge is essential for effective problem-solving

To clear NCR, identify root cause, implement corrective actions, verify effectiveness, and close out the NCR.

• Identify the root cause of the non-conformance.

• Implement corrective actions to address the root cause.

• Verify the effectiveness of the corrective actions through testing or inspection.

• Close out the NCR once the corrective actions have been successful.

• Document all steps taken in the NCR clearance process.

List of manufacturing processes, casting defects, and welding defects.

• Manufacturing processes: machining, forging, stamping, extrusion, injection molding, etc.

• Casting defects: porosity, shrinkage, cold shuts, misruns, etc.

• Welding defects: lack of fusion, porosity, cracks, undercutting, etc.

SDLC stands for Software Development Life Cycle and STLC stands for Software Testing Life Cycle.

• SDLC is a process followed for developing software from planning to deployment.

• STLC is a process followed for testing software from planning to deployment.

• SDLC includes phases like requirements gathering, design, development, testing, deployment, and maintenance.

• STLC includes phases like test planning, test design, test execution, and test closure.

• Both SDLC and STLC are important f...read more

SPC stands for Statistical Process Control. It is a method used to monitor and control a process to ensure it operates within specified limits.

• SPC involves collecting and analyzing data to identify and reduce process variation.

• It uses statistical techniques to determine if a process is stable and capable of meeting customer requirements.

• Control charts are commonly used in SPC to visually display process data and identify any out-of-control conditions.

• SPC can be used to improv...read more

Micrometer list count formula is the number of divisions on the micrometer scale multiplied by the value of one division.

• The formula is: Micrometer list count = Number of divisions on the micrometer scale x Value of one division

• The micrometer list count is used to measure the thickness or diameter of small objects

• For example, if the micrometer scale has 50 divisions and the value of one division is 0.01mm, then the micrometer list count would be 0.5mm

Poka Yoke is a mistake-proofing technique used in manufacturing to prevent errors before they occur.

• Poka Yoke involves designing processes or products in a way that prevents mistakes or defects.

• Examples include using color coding for different parts to avoid mix-ups, or designing a shape that only fits in one way to prevent assembly errors.

• The goal of Poka Yoke is to eliminate defects by preventing human errors.

An inspection test plan is a document outlining the procedures and criteria for inspecting and testing products or processes.

• An inspection test plan includes details on what will be inspected, how it will be inspected, and the acceptance criteria.

• It helps ensure that products meet quality standards and specifications.

• Examples of items in an inspection test plan include inspection checklists, testing methods, and sampling plans.

Address the issue directly and provide constructive feedback to improve team performance.

• Have a one-on-one meeting with each team member to discuss concerns and provide feedback.

• Offer additional training or resources to help team members improve their performance.

• Encourage open communication and collaboration within the team to address any issues or challenges.

• Set clear expectations and goals for the team to work towards.

• Provide support and guidance to help team members succe...read more

Control plan details the steps to maintain quality during production, while PFD outlines the process flow and potential failure points.

• Control plan focuses on quality control during production

• PFD outlines the process flow and potential failure points

• Control plan includes details on inspection points, frequency, and methods

• PFD is a visual representation of the process steps and potential failure modes

Yes, I am able to create quality documents by ensuring accuracy, clarity, and compliance with standards.

• I have experience creating quality documents such as quality plans, test protocols, and validation reports.

• I pay attention to detail to ensure accuracy in all documentation.

• I ensure that all documents are clear, concise, and easy to understand for all stakeholders.

• I follow industry standards and regulations to ensure compliance in all documentation.

Dynamic xpath is a way to locate elements on a web page based on changing attributes or positions.

• Use functions like contains(), starts-with(), or ends-with() to create dynamic xpaths

• Avoid using indexes in xpaths as they can change with page updates

• Consider using unique attributes or text within the element to create a reliable xpath

Program to count consecutive characters in a string

• Iterate through the string and compare each character with the next one

• Maintain a count for each character and append to the output string when a different character is encountered

• Example: input 'aabbccc' -> output 'a2b2c3'

Passing criteria is the set of requirements that must be met for a product or process to be considered acceptable. MDD stands for Medical Device Directive and OMC stands for Orthopedic Medical Device Classification.

• Passing criteria are the specific standards or benchmarks that must be achieved for a product or process to be deemed acceptable.

• MDD (Medical Device Directive) is a set of regulations that govern the manufacturing and distribution of medical devices in the European...read more

Profile of surface refers to the 3D deviation of a surface from its perfect form, while Profile of line refers to the 2D deviation of a line from its perfect form.

• Profile of surface is a 3D measurement, while Profile of line is a 2D measurement

• Profile of surface considers the entire surface, while Profile of line focuses on a specific line on the surface

• Profile of surface is used to evaluate the overall shape and form of a surface, while Profile of line is used to evaluate th...read more

Sheet metal parts can be measured using various tools and techniques to ensure accuracy and quality.

• Use calipers to measure dimensions such as length, width, and thickness.

• Utilize a micrometer for more precise measurements of thickness.

• Perform a visual inspection to check for any defects or imperfections.

• Use a coordinate measuring machine (CMM) for complex geometries and tight tolerances.

• Verify measurements against engineering drawings or specifications.

• Consider using optical...read more

Yes, I have knowledge about motors.

• I have experience working with various types of motors such as AC, DC, and stepper motors.

• I am familiar with motor control systems and their components such as drivers, encoders, and sensors.

• I have worked on projects involving motor testing and troubleshooting.

• I have knowledge of motor specifications and their applications in different industries.

• I am proficient in using tools such as multimeters and oscilloscopes for motor analysis.

Customer complaints can be controlled by implementing a robust complaint management system.

• Establish a complaint management process

• Ensure prompt and efficient complaint handling

• Analyze complaints to identify root causes

• Implement corrective actions to address identified issues

• Monitor and track complaint resolution

• Continuously improve products and services based on customer feedback

Primary steel is produced directly from iron ore, while secondary steel is made from recycled scrap metal.

• Primary steel is produced in integrated steel mills using iron ore and other raw materials.

• Secondary steel is made by recycling scrap metal in electric arc furnaces or basic oxygen furnaces.

• Primary steel is typically of higher quality and purity compared to secondary steel.

• Examples of primary steel include hot rolled coils and cold rolled coils, while examples of secondar...read more

Pin bars are used for slab beams to provide additional support and stability.

• Pin bars help distribute the load evenly across the slab beam.

• They prevent the slab beam from sagging or bending under heavy loads.

• Pin bars also help in reducing deflection and increasing the overall strength of the structure.

SST testing standard for zinc plating and powder coating involves subjecting the coatings to a salt spray test to evaluate their corrosion resistance.

• SST testing is a common method used to assess the corrosion resistance of coatings.

• For zinc plating, the ASTM B117 standard is typically followed for SST testing.

• For powder coating, the ASTM D1654 standard is commonly used for SST testing.

• The coatings are exposed to a salt spray solution for a specified period of time, and the a...read more

The list count of a vernier caliper is typically 20 or 50.

• The list count refers to the number of divisions on the vernier scale.

• A 20-count vernier caliper has 19 divisions on the scale, while a 50-count has 49 divisions.

• The list count determines the precision of the caliper's measurements.

Material inspection procedure involves thorough examination of raw materials to ensure they meet quality standards.

• Receive incoming materials and verify against purchase orders

• Conduct visual inspection for any defects or damage

• Perform measurements and tests to check for quality and compliance

• Document inspection results and communicate any issues to relevant parties

TestNG is a testing framework for Java that provides various features for testing applications.

• TestNG is an open-source testing framework that is inspired by JUnit and NUnit.

• It allows the creation of test cases, test suites, and test configurations.

• TestNG supports various annotations for test configuration and execution control.

• It provides features like parallel test execution, data-driven testing, and test dependency management.

• TestNG generates detailed test reports and supp...read more

8D methodology is a problem-solving approach used to identify, correct, and prevent recurring problems in manufacturing and other industries.

• 8D stands for 8 disciplines, each representing a step in the problem-solving process

• Steps include forming a team, defining the problem, implementing and verifying interim containment actions, identifying root causes, implementing permanent corrective actions, preventing recurrence, recognizing team efforts, and standardizing processes

• Exa...read more

The process of a plant involves several stages from seed to harvest.

• Planting the seed in soil or a growing medium

• Providing adequate water, sunlight, and nutrients

• Germination and growth of the plant

• Pruning and maintenance of the plant

• Harvesting the plant when it reaches maturity

Dealing with customer complaints requires active listening, empathy, and prompt resolution.

• Listen actively to the customer's complaint and acknowledge their concerns.

• Express empathy and apologize for any inconvenience caused.

• Investigate the issue thoroughly and provide a prompt resolution.

• Follow up with the customer to ensure their satisfaction and prevent future complaints.

• Maintain a positive attitude and remain professional throughout the process.

Heat treatment process involves heating and cooling metals to alter their physical and mechanical properties.

• Heat treatment is used to improve hardness, strength, toughness, and ductility of metals.

• Common heat treatment processes include annealing, quenching, tempering, and normalizing.

• Annealing involves heating the metal to a specific temperature and then slowly cooling it to make it softer and more ductile.

• Quenching involves rapidly cooling the metal to increase its hardnes...read more

Our manufacturing process involves precision machining, assembly, testing, and quality control.

• Precision machining is used to create components with tight tolerances.

• Assembly involves putting together the components to create the final product.

• Testing is conducted to ensure the product meets specifications and standards.

• Quality control measures are in place to monitor and improve the manufacturing process.

• Examples: CNC machining, automated assembly lines, product testing equi...read more