200+ Senior Quality Engineer Interview Questions and Answers

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

Chemical admixtures can improve the workability, durability, and strength of concrete.

• Chemical admixtures can improve the workability of concrete by reducing water content or increasing slump.

• They can enhance the durability of concrete by reducing permeability, increasing resistance to freeze-thaw cycles, or inhibiting corrosion of reinforcement.

• Certain chemical admixtures can accelerate or retard the setting time of concrete.

• Examples of chemical admixtures include water redu...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

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.

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

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

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

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

Plastic testing involves evaluating the physical, mechanical, and chemical properties of plastic materials to ensure quality and safety.

• Plastic testing includes tests for strength, flexibility, impact resistance, and thermal properties.

• Common testing methods for plastics include tensile testing, impact testing, hardness testing, and thermal analysis.

• Chemical testing is also important to assess the stability and compatibility of plastics with various substances.

• Plastic testing...read more

Preventive action in CAPA is a proactive approach to prevent potential issues from occurring.

• Preventive action is taken before a problem occurs

• It involves identifying potential issues and taking steps to prevent them

• Examples include implementing new procedures, training employees, and improving equipment

• Preventive action is an important part of a comprehensive CAPA system

ISAO stands for Information Sharing and Analysis Organization. It is a standard requirement for cybersecurity.

• ISAO is a collaboration between private sector, government, and non-profit organizations to share information about cyber threats and vulnerabilities.

• ISAOs must adhere to certain standards set by the Department of Homeland Security (DHS) to ensure the quality and effectiveness of information sharing.

• ISAOs must also follow guidelines for protecting sensitive informatio...read more

Different materials such as SS, LAS, CS, DT, NDT are commonly used in engineering for various applications.

• SS stands for stainless steel, commonly used for its corrosion resistance.

• LAS refers to low alloy steel, known for its high strength and toughness.

• CS stands for carbon steel, often used in structural applications.

• DT stands for ductile iron, known for its high strength and ductility.

• NDT methods include ultrasonic testing, radiography, and magnetic particle inspection.

Authentication scenarios include single sign-on, multi-factor authentication, and passwordless authentication.

• Single sign-on allows users to access multiple applications with a single set of credentials.

• Multi-factor authentication requires users to provide two or more forms of identification, such as a password and a fingerprint.

• Passwordless authentication uses methods such as biometric identification or one-time codes to authenticate users without requiring a password.

• Other ...read more

Raw material defects are imperfections or flaws in the materials used in manufacturing processes.

• Raw material defects can include cracks, chips, dents, scratches, discoloration, and impurities.

• These defects can impact the quality and performance of the final product.

• Examples of raw material defects include a batch of steel with visible cracks, a shipment of plastic with discoloration, and a roll of fabric with tears.

• Inspecting raw materials for defects is crucial to ensure th...read more

The process at our company is a systematic approach to achieving quality in our products and services.

• Our process involves defining clear quality objectives and standards.

• We establish and document procedures for each step of the quality control process.

• Responsibilities are assigned to individuals or teams to ensure accountability.

• Regular monitoring and measurement of key quality indicators are conducted.

• We analyze data and identify areas for improvement.

• Corrective and prevent...read more

Performance testing is important to ensure that the system can handle expected user load and provide a good user experience.

• Identifies bottlenecks and performance issues before they impact users

• Helps optimize system performance and resource utilization

• Ensures that the system can handle expected user load and provide a good user experience

• Examples: load testing, stress testing, endurance testing

Machining process involves removing material from a workpiece using cutting tools at various stations.

• Machining process is used to create precise and complex shapes in metal, plastic, and other materials.

• It involves cutting, drilling, milling, and turning operations.

• Each station in the process has a specific tool and function, such as roughing, finishing, or drilling.

• Examples of machining stations include lathes, milling machines, and drill presses.

Process audit is a systematic examination of processes to ensure they are being carried out as planned. Product audit is an examination of the final product to ensure it meets quality standards.

• Process audit focuses on the methods and procedures used to create a product or deliver a service

• Product audit focuses on the final output to ensure it meets quality standards

• Process audit helps identify areas for improvement in the production process

• Product audit helps ensure that the...read more

I prefer to discuss the salary range for this position before disclosing my current ctc and expectation.

• I am open to negotiation based on the responsibilities and requirements of the role.

• I am looking for a competitive salary package that aligns with my experience and skills.

• I am willing to consider other benefits such as health insurance, retirement plans, and vacation time.

• I am confident that we can come to a mutually beneficial agreement.

CAPA stands for Corrective and Preventive Actions. It is a systematic approach to identifying, investigating, and resolving quality issues.

• CAPA is used in quality management systems to address non-conformances and prevent their recurrence.

• Corrective actions are taken to eliminate the root cause of a non-conformance.

• Preventive actions are implemented to prevent potential issues from occurring in the future.

• CAPA processes often involve root cause analysis, corrective action pla...read more