manufacturing explain production process material used product

techsuch May 9, 2021 0 Comments

Top 20 Manufacturing Production Interview Questions & Answers1) Explain the term BOM?BOM stands for Bill Of Materials; it is a list of item or parts that makeup aproduct assembly. For example, a lawn mower requires a handle assembly, metaldeck assembly, a control assembly, motor and blade assembly.2) Explain what is DCR?DCR stands for Document Change Request, a change request which addresses abouta problem with a document, SOP (standard operating procedure) or specificationand propose a change to fix it.3) Explain what is Kanban?Kanban is scheduling system which advises manufacturers about how much toproduce, 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 thefactory floor with the motive of reducing the total time required to producean order.5) Explain what is Six Sigma?Six sigma is a data-driven methodology and approach for eliminating defects inany 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 necessaryinformation about company’s design and operational controls, including issuereporting, monitoring, continuous improvement and training, to make sure thatcompany delivers continuous product.8) Explain what is batch production?Batch production is a manufacturing technique, where components or goods areproduced in groups and not in a continuous stream. This methodology is mainlyused 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, decreaseproduction 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 theprocess is referred as “factory overhead”, excluding the cost of materials anddirect labours.12) List out some of the examples of factory overhead?Following are the overheads a production manufacturing engineer has toconsider: * 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 salaries13) Explain how to supervise in a manufacturing unit?Supervising a manufacturing process includes attending to the individualphases of the production. Also, manufacturing supervisor should have a closeeye 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 materialinto the work in process which includes raw material, labour and factoryoverhead. You can calculate all the below factors to know the costing for themanufacturing work in progress. * labour costs * Raw material inventory costs * Production cost * Cost of ending work in process for the accounting period15) 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 ordertracking used to determine a returned item’s origination. It is often used ina transaction where a customer returns goods to the manufacturer forreplacement or repair purpose.17) Explain what is SCAR (Supplier Corrective Action Request)?Manufacturers are highly dependent on their raw material suppliers, tocommunicate with them effectively SCAR is used. It is a change request thatmentions the issues with the process or material from a supplier and ask for aresolution. It sometimes also includes the details about how the complaintshould 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 andMaterial Management. Some of the companies that provide the manufacturingsoftware solution are SAP, Oracle ERP system, etc.19) Explain what is GMP?GMP is a good manufacturing practice and is recognized worldwide for thecontrol 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.

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