Manufacturing Production Interview Questions
Here are Manufacturing Production interview questions and answers for freshers as well as experienced manufacturing engineer candidates to get their dream job.
1) Explain the term BOM?
BOM stands for Bill Of Materials; it is a list of item or parts that makeup a product assembly. For example, a lawn mower requires a handle assembly, metal deck assembly, a control assembly, motor and blade assembly.
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2) Explain what is DCR?
DCR stands for Document Change Request, a change request which addresses about a problem with a document, SOP (standard operating procedure) or specification and propose a change to fix it.
3) Explain what is Kanban?
Kanban is scheduling system which advises manufacturers about how much to produce, what to produce and when to produce. In this system, inventory is re-filled only when visual cues like an empty bin or cart is seen.
4) Explain what is MES?
MES stands for a system that manages and controls the production on the factory floor with the motive of reducing the total time required to produce an order.
5) Explain what is Six Sigma?
Six sigma is a data-driven methodology and approach for eliminating defects in any process from manufacturing to transactional and from product to service.
6) What is the difference between lean manufacturing and JIT (Just-in-Time) Manufacturing?
- Lean Manufacturing: It takes the concept of JIT and re-examines it from the customer point of view. Anything that is produced should add something of valuable to the customer’s requirement. For example, if you are making stereo system for a luxury car, you will think from the customer point of view like sound quality, durability, space occupancy, loud or medium sound, etc.
- JIT (Just-in-Time): This methodology is designed to ensure that a product or part would arrive just in time to be used. This technique saves the cost behind the unused inventory, and eliminating the need of piling up inventory.
7) Explain what is QMS?
QMS stands for Quality Management System; it documents all necessary information about company’s design and operational controls, including issue reporting, monitoring, continuous improvement and training, to make sure that company delivers continuous product.
8) Explain what is batch production?
Batch production is a manufacturing technique, where components or goods are produced in groups and not in a continuous stream. This methodology is mainly used when similar items are produced together.
9) What is the challenge in manufacturing products?
Main challenge in manufacturing is to develop better production processes, ensure the right material and component supplies at the least cost, decrease production time, eliminate wastage and maintain quality in the final product.
10) List out the factors that can affect the manufacturing process?
The factors affect the manufacturing process are
- Supplies: A well-managed supply and inventory is very crucial in order to run manufacturing process smoothly. The manufacturers must brace themselves up and ready to overcome any unexpected delays in supplies due to weather or transportation hindrance.
- Equipment: Equipment’s are the central unit for any manufacturing plant; regular maintenance are utmost necessary to avoid a breakdown in the middle of production. Identify the means of improving the efficiency of every part of the equipment.
- Factory Overhead: Without power supply, manufacturing is not possible. Always keep plan B ready in case of temporary power cut down.
- Special Parts: Replacing any special spare parts with different specification may slow down your production, so before ordering any special spare parts ensure it fits your demand especially if it is imported from long distance.
- Work Force: Human resource is equally important and plays a major role in manufacturing unit.
11) Define the term “factory overhead”?
During the manufacturing process, whatever the cost is incurred during the process is referred as “factory overhead”, excluding the cost of materials and direct labours.
12) List out some of the examples of factory overhead?
Following are the overheads a production manufacturing engineer has to consider:
- Factory rent
- Utilities used in the unit
- Costs behind equipment set up
- Costs behind equipment maintenance
- Production unit supplies
- Insurance covered on equipment’s and production facilities
- Fringe benefits
- Depreciation
- QA Salaries
- Property taxes on manufacturing facilities
- Material management salaries
13) Explain how to supervise in a manufacturing unit?
Supervising a manufacturing process includes attending to the individual phases of the production. Also, manufacturing supervisor should have a close eye on the inventory that going to be used.
- Step 1: Keep the records of different phases of manufacturing also analyse whether the amount of product produced by the crew is enough to meet the demand
- Step 2: Look for the bottlenecks in the unit and see how you can eliminate it
- Step 3: Keep the track of inventory and try to reduce the liquid capital used after unused material
- Step 4: Examine the final goods to determine whether they meet the company’s quality standards.
14) Explain how can you calculate manufacturing work in progress?
Manufacturing work in progress is when manufacturing firm transforms material into the work in process which includes raw material, labour and factory overhead. You can calculate all the below factors to know the costing for the manufacturing work in progress.
- labour costs
- Raw material inventory costs
- Production cost
- Cost of ending work in process for the accounting period
15) Explain what is product report?
A product report is a general term used to represent design, manufacturing, quality, sales and repair information about a product.
16) Explain what is RMA?
RMA stands for Return Material Authorization; it is a financial and work order tracking used to determine a returned item’s origination. It is often used in a transaction where a customer returns goods to the manufacturer for replacement or repair purpose.
17) Explain what is SCAR (Supplier Corrective Action Request)?
Manufacturers are highly dependent on their raw material suppliers, to communicate with them effectively SCAR is used. It is a change request that mentions the issues with the process or material from a supplier and ask for a resolution. It sometimes also includes the details about how the complaint should be addressed.
18) What are the softwares which can be useful in manufacturing unit?
In manufacturing unit, software that can be useful are Manufacturing ERP and Material Management. Some of the companies that provide the manufacturing software solution are SAP, Oracle ERP system, etc.
19) Explain what is GMP?
GMP is a good manufacturing practice and is recognized worldwide for the control and management of manufacturing and quality control testing of foods, medical devices and pharmaceutical products.
20) Explain what are the approach used in manufacturing for QA?
For QA in manufacturing techniques used are
- Acceptance sampling: In this testing, a random sample is picked from the batch rather than testing the whole batch.
- Statistical process control: Through the use of control charts and data collected for the samples at the various stages of production a manufacturing product can be monitored
- Troubleshooting studies: At the end of the line product, a trouble-shooting study can be carried out to see whether the changes in the inputs are associated with the output variables.
These interview questions will also help in your viva(orals)
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Electronically commutated (EC) motors, sometimes called brushless DC (BLDC) motors, are a boon to the refrigeration industry that relies on continuously running motors. These quiet wonders can offer efficiencies in more ways than just energy savings. If you haven’t done it already, we can give you 7 excellent reasons to consider switching to EC motors from older shaded pole motors:
7 Reasons Why You Should Switch to an EC Motor
- We hinted at it already, but EC motors are quiet. You can barely hear them running.
- EC motors are highly efficient, they can be up to 70 percent more energy efficient than shaded pole motors.
- Because they use less energy, EC motors run much cooler.
- With less wear and tear from temperature spikes, EC motors last longer.
- EC motors meet the energy efficiency standards outlined by the U.S. Department of Energy.
- EC motors are reprogrammable. As a result, a single SKU can be used for multiple operations, increasing the flexibility of your motor inventory.
- Over time, EC motors are less expensive as a cost, though they are more expensive right out of the gate.
We mentioned the flexibility of these marvelous motors. In the following video, Dave Purvis, director of motor business development at East West, demonstrates how easy it is to reprogram an EC motor. Take a look:
Are you wondering why EC motors are so much better than older shaded pole motors? Design is a key differentiator, but so are the materials used to make EC motors.
In the past, motors have been made from metal; a sturdy material, certainly, but one that was easily compromised by extreme temperature variations, corrosion, vibration or improper electrical grounding. Instead, EC motors are made with sturdy plastics, reinforced with glass fibers. New advanced plastics are tough enough to replace steel and aluminum throughout the motor either as enclosures, structural parts or insulating material and do a great job of diffusing heat and vibration from the motor.
How IP Ratings Protect Your EC Motor
We ask a lot of our motors, especially those used in commercial refrigeration systems. In addition to the continuous use they endure, EC motors are exposed to all the common hazards that weaken systems including:
- Dust buildup
- Water exposure during washdown
- Water condensate on metal parts
- Ice build up
- Water from melting ice/defrost
Motors receive only so much protection built-in via design. The industry also relies on a rating system called an Ingress Protection (IP) rating code (IEC 60529). These ratings define the levels of sealing effectiveness an electrical enclosure maintains against such contaminants as objects (i.e., tools, dirt) or moisture.
The IP rating is represented by two digits — I P X X. The two digits refer to separate levels of protection; the first place demonstrates the level of protections versus solid objects, while the second place demonstrates the level of protection against liquids. The higher the number, the higher the level of protection.
For example, an EC motor with an IP54-rated motor would provide limited entry of dust and water as opposed to an IP67-rated motor, which is considered dust tight and can even protect a motor in the event of immersion in water during short periods of time.
Questions to Ask a Prospective Motor Supplier
Qualifying a new supplier can be tedious, but you probably have an idea of the attributes you’re looking for. Here are some questions we’ve added that will help you narrow down your choices, so you can find the right motor supplier for your company.
Trust
It’s all important to know that your supplier relationship is built on trust. This is a combination of research, references and intuition. If something feels off, wait and see if you can figure out what it is that’s bothering you. Here's a hint: Take a look at their website. Has it been refreshed? Do they have a real email address? Sometimes something as simple as having an up-to-date website sends a signal of professionalism.
Questions to ask:
- How long have you been in business?
- Do you hold patents? Do you have an actual office address?
- What’s your role? Are you the manufacturer, or are you just the trader or wholesaler?
Transparency
Transparency goes hand in hand with trust. There has to be an open door, open floor policy with your supplier or doubt is inevitable. That’s relationship 101.
Questions to ask:
- Am I welcome to visit your office, factory and warehouse? How much notice do you require?
- How easy is it to follow all the links of your supply chain?
Technical Know-how
EC motors are a specialized subset of motors that require unique design skills. Does your team have this experience? Do they know what they’re doing?
Questions to ask:
- Have you built an EC motor for my application before?
Scale
Okay, they’ve got your business now, but do they have the ability and desire to grow with your company?
Questions to ask:
- Can you make 1,000 per month or 10,000 per month if demand spikes?
- How quickly can you scale up my product when it begins to gain market share?
Quality
It's essential to determine whether you and your supplier have similar quality values. The best way to get this information is to ask to see their Advanced Product Quality Planning (APQP). The APQP is a quality matrix that companies use to develop products in a given industry. Looking at your supplier’s quality plan will give you the best idea of how they will handle your business.
Questions to ask:
- How long will your EC motor work?
- Do you have a global quality plan? Can I see it?
Good things take time. A supplier relationship isn’t one you enter into lightly. The object of these questions isn’t to make anyone feel uncomfortable, but to ensure that you’re engaged with the correct supplier. Take the time to ask the questions and don’t settle until you get the answers back that satisfy you.
How Much Money Can I Save Using EC Motors?
We’ve been clear about the upfront costs of EC motors. They do cost more than PSC motors. That is a fact. But what is also a fact, is that EC motors are so incredibly energy efficient that it does not take long recoup the investment in savings.
We figured out an example of the energy savings from EC motors using everyone could relate to — grocery stores.
And now we’re getting somewhere. Of course, many companies would be happy with a savings of substantially less than $700 million. I know ours would be.
So, yes, you will pay more for EC motors, but through simple energy savings, those motors will quickly pay you right back.
We've thrown a lot of information at you. Whether or not you're ready to make the switch to EC motors, this blog post probably stirred up questions. If that's the case, click on the download below or get in touch! We're happy to answer talk with you.