1. What Is Difference Between Production Engineering And Industrial Engineering?

Production Engineering:– It is a branch of engineering which is a combination of manufacturing

technology with management service.
Industrial Engineering:– It is a branch of engineering dealing with the optimization of complex
processes such as improvement, development , implementation of integrated systems.
2. What Is Difference Between Jigs And Fixture?
Jigs and fixtures are the devices used to manufacture large amount of duplicate parts accurately.
Jigs:- A device that does both functions such as holding the work and guiding a tool is called Jigs.
Types –  Drill Jigs and Boring Jigs. 
Fixtures:- It is a production tool that holds, locates and support the work securely so that required
machining operations can be performed. Types – Milling Fixture, Profile Fixture.
3. How Did You Reduce The Downtime & Increased The Production?
 I reduced downtime & increase the production by using following steps:-
o By providing the maintenance activity on time if the problem comes arise on any
machine.
o By providing sufficient raw material/tools/bits on machine.
o I made the best plant layout for machines and arranging them in line according to
the next process.
o And, By making time study report of all components those are being manufactured
on the machines. After then, I fixed the target for making these components.
o By using Manpower accurately & removing useless work. Also, implementing 5S,
Kaizen activities to increase the production and reduce the down time.
4. Difference Between Production And Manufacturing?
Manufacturing means a process of converting raw material into finish products by using various
processes on machine.
Production means a process of converting inputs into outputs.
5. How Did You Improve The Quality During Production?
I improve the quality during production by using following steps:-
o By checking the components after every half hour.
o By checking the accuracy of tools & quality of material used for manufacturing the
products.
o By giving run charts to the workers so they can check as they are going to be within
tolerance. Run chart provides them continuous production with quality.
o By using good quality of coolant/cutting fluid for manufacturing process.
o By giving good communication channel between the workers and me.

6. How Do You Maintain Discipline On The Floor As The Production Engineer?

 I have made a good communication channel between the workers and me. I give the daily
production target to the workers which make them busy to complete their work. I give my full
attention on shop floor and we take strict action if any worker starts gossiping during working
hours.
7. How Do You Plan Various Shifts And Daily Production?
We get the weekly/monthly basis schedule from our customers. After getting the same schedule
from PPC department, I do plan for various shifts and report to workers by displaying on the notice
board after the approval of the production manager. I provide daily target sheets to the workers
and also check the sufficient raw material, tools, coolant & unrepaired machine on the workshop.
8. How Do You Install The New Machines And Layout Preparation As A Production Or
Process Engineer?
Firstly, we make the process plan of the components and according to it, I draw the layout of the
machines and make sure that machines should be in arrangement according to the next
processes.
 Then, I also check to maintain the distance between the machines. We install the machines for
maximum time saving and provide proper safety to the workers.
9. How Did You Reduce The Cycle Time Of Machines To Increase The Production?
I reduced the cycle time of machines by using following methods:-
o Replace old machines with new one or giving servicing to the old machines on time.
o By using of good quality of tools, coolant and raw material.
o With the selection of active workers and impart training to them.
o By making the time study report of all components those are running on machines.
10. How Many Workers Are Working Under You?
I am working as production engineer or supervisor. Around 40/50 workers are reporting to me in
my line. We have 2/3 GET and DET those are getting training under me.
11. What Is Difference Between Lean Manufacturing And Jit (just In Time)?
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.
12. What Is The Least-count Of Vernier Caliper & Micrometer?
A) Vernier Caliper Least Count
LC = ( Value of 1 Main Scale Division ) / ( Total number of vernier scale divisions )
LC =  0.1 mm = ( 1 mm / 10 divisions )
LC of Vernier Caliper = 0.1 mm
B) Micrometer are also called Screw Gauge. 
Least count of Micrometer 
Least count of Micrometer
Least Count of Micrometer= 0.01 mm
13. 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.
14. 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.
15. 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.
16. 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.
17. What Are The Software’s 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.
18. What Is Product Report?
 A product report is a general term used to represent design, manufacturing, quality, sales and
repair information about a product.
19. 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.
o Labour costs
o Raw material inventory costs
o Production cost
o Cost of ending work in process for the accounting period.
20. 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.
21. 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.
22. 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.
23. 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.
24. 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.
25. 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.
26. Which One Is The Hardest Material On Earth?
Diamond > Carbide > HSS ( High Speed Steel ) > Mild Steel > Low Carbon Steel
27. What Is 5 S ?
5S describes how to describe a work space for efficiency and effectiveness by identifying and
storing the items.
1S -Sorting – To eliminate all the unnecessary tools, parts and instructions.
2S -Setting in order – Everything should be in its place and the place for each item should be
clearly labeled.
 3S- Sweeping – Keep the workplace tidy and organized.
4S- Standardizing – Work place and tools should be consistent and standardized.
5S- Self Discipline –  Maintain the self discipline on the floor for effective efficiency. 
28. How Internal Gears Can Be Cut?
Internal Gear can be made by shaping with the pioneer cutter.
29. What Is Rake Angle?
Rake angle is the angle between the face of the cutting tool ( Rake Face ) and the normal to the
cutting direction.
30. What Type Of Machines & Tools Is Used In Automobile Industry?
o For Conventional Machines such as Lathe, milling machine, drilling machine,
grinders company use the twist drill , twist drill bit with morse taper shank drills of HSS
( High Speed Steel ) material.
o For CNC Machines like CNC Lathe, VMC, company use the bits of carbide material.
Bits are made from the high carbon steel, HSS, Carbide. Carbide is used for very hard
material.
o HSS drills in sizes such as M2, M35, M42 Grades.
o Carbide tip tools as per ISO standards are in K10,K20,P10,P20, P30 & P40.
31. What Is Heat Treatment And Why Is It Done?
Heat treatment can be defined as a combination of processes or operations in which the heating
and cooling of a metal or alloy is done in order to obtain desirable characteristics without
changing the compositions.
Some of the motives or purpose of heat treatment are as follows:-
o In order to improve the hardness of metals.
o For the softening of the metal.
o In order to improve the machinability of the metal.
o To change the grain size.
o To provide better resistance to heat, corrosion, wear etc.
Heat treatment is generally performed in the following ways:
o Normalizing
o Annealing
o Spheroidising
o Hardening
o Tempering
o Surface or case hardening
32. What Are The Different Types Of Springs And Explain Them Briefly?
Springs can be broadly classified into the following types:
Helical Springs: These springs as their name suggests are in coil form and are in the shape of
helix. The primary purpose of such springs is to handle compressive and tensile loads. They can
be further classified into two types: compression helical spring and tension helical spring each
having their own unique areas of application.
Conical and Volute springs: Both these spring types have specialized areas of usage where
springs with adaptable rate according to the load is required. In case of conical springs they are
wound so as to have a uniform pitch while on the other hand volute springs are wound in a slight
manner of a parabolic. 
Torsion Springs: The characteristics of such springs are that they tend to wind up by the load.
They can be either helical or spiral in shape. These types of springs are used in circuit breaker
mechanisms.
Leaf springs: These types of springs are comprised of metal plates of different lengths held
together with the help of bolts and clamps. Commonly seen being used as suspensions for
vehicles.
 Disc Springs: As the name suggests such types of springs are comprised of conical discs held
together by a bolt or tube.
Special Purpose Springs: These springs are all together made of different materials such as air
and water.
33. What Are The Different Types Of Brakes And Explain Them Briefly?
Brakes can be classified on the basis of their medium used to brake, they are as follows:
Hydraulic Brakes: These brakes as their name suggest use a fluid medium to push or repel the
brake pads for braking.
Electric Brakes: These brakes use electrical energy to deplete or create a braking force.
Both the above types of breaks are used primarily for applications where a large amount of energy
is to be transformed.
Mechanical Brakes: They can be further classified on the basis of the direction of their acting
force: Radial Brakes: As their names suggests the force that acts on the brakes is of radial
direction. They can further be classified into internal and external blades. Axial Brakes: In these
types of brakes the braking force is acting in an axial direction as compared to radial brakes.
34. What Are Bevel Gears And What Are Its Types?
Bevel gears are the type of gears in which the two shafts happen to intersect. The gear faces
which are tooth bearing are conical in shape. They are generally mounted on shafts which are 90
degrees apart but they can be made to work at other angles as well.
The bevel gears are classified into the following types on the basis of pitch surfaces and shaft
angles:
o Mitre Gears: These types of gears are similar to each other ie. they have the same
pitch angles and contain the same number of teeth. The shaft axes intersect at 90
degrees angle.
o Angular bevel gears: When two bevel gears connect at any angle apart from 90
degrees.
o Crown bevel gears: When the two shaft axes intersect at an angle greater than 90
and one of the bevel gears have a pitch angle of 90 degrees they are known as crown
bevel gears.
o Internal bevel gears: In these type of gears the teeth on the gears is cut on the
inside area of the pitch cone.
35. What Is A Bearing? What Are The Different Types Of Bearings?
Bearing is a device that helps smoother movement with minimal friction which in turn helps
enhances efficiency and speed. Considering two types of loading, radial and thrust, there are
different types of bearings which help handle these loads. The basic difference in the types of
loads is essentially due to their ability to handle weight and different kinds of loads for various
applications.
Different types of bearings are:
o Ball bearing
o Roller bearing
o Ball Thrust bearing
o Roller thrust bearing
o Tapered roller bearing
o Magnetic bearings
o Giant Roller Bearing
36. What Is A Process Flow Diagram?
A Process Flow Diagram is a user friendly, simplified sketch which illustrates general plant
streams, major equipments and key central loops and shows the relationship between major
components in the system. By using symbols to identify instruments and vessels it describes the
primary flow course. They also provide e detail of mass/energy balance data along with stream
composition and physical properties, however do not show minor components.
37. Which Is The Hardest Material On Earth?
Diamond is currently the hardest material, made up of carbon atoms which cannot move. Carbon
is the only atom that can have four electrons in the second shell surrounding the carbon nucleus,
precisely why making a diamond the hardest material. However, there also are claims by a few to
a new rare material called Wurtzite Boron Nitride which has a structure similar to a diamond but
has some other atoms in place of carbon.
38. What Kind Of Pipes Are Used For Steam Lines?
Pressure and temperature are two of the most important factors to be considered before selecting
the type of material to be used. Steam is a compressible gas due to which the capacity of the pipe
line depends on the size of the pipes and pressure of the steam. Since steam at even low pressure
can be dangerous, extra care is to be taken. Galvanized pipes are usually not used for steam.
Pipes made of mild steel with welded fittings are instead largely used.
39. Explain The Difference Between Pipe And A Tube?
A pipe is measured based on its inner diameter (ID) whereas a tube is measured based on the
outer diameter (OD). Other than the dimensions there is no major difference between the two.
40. What Is The Difference Between Torque And Power?
While power determines the speed of a vehicle, torque determines the times in which that speed
can be reached. The greater the torque figure, the faster the acceleration. The more torque in the
engine, the faster you accelerate. Power is the rate at which work is done, so it is basically the
potential of the engine.
41. What Is Torque?
Torque is the force that causes rotation. It is a measure of how much force is acting on an object
making it rotate.
42. Explain Why Diesel Engine Is Known As High Torque And Petrol Engine As High Speed
Engine?
Each power stroke in a petrol engine releases more heat and is converted into mechanical energy
due to a higher rate of burning. This is the reason petrol engine has higher power and acceleration.
Diesel engine is a compression ignition engine with higher compression ratio, therefore extreme
pressure is high. Since the piston of a diesel engine is larger, more torque is delivered in produced.
43. Why Do Heavy Vehicles Use Diesel Engine?
The compression ratio of diesel engine is higher than the petrol engine, the reason for producing
higher torque. The efficiency of diesel engine increases with load. Diesel produces slow energy on
burning of fuel and the efficiency of the engine increases with load which is why diesel engine is
suitable and largely used for heavy vehicles.
44. Explain The Types Of Sensors?
o Temperature Sensor:- This device collects information about the temperature from
a source and converts it to a form which is understandable by another device or
person. Glass thermometer is the best example where mercury acts as the temperature
sensor.
o IR Sensors:- This device detects and/or emits infrared radiation to sense a
particular phase in the environment. Mostly thermal radiation is emitted by all the
objects in the infrared spectrum. This type of radiation is not visible to the human eye
but the infrared sensor detects it.
o UV Sensors:- These sensors measure the intensity of the ultraviolet radiation. This
form of electromagnetic radiation has wavelengths which are longer than x-rays yet
shorter than visible radiation. UV sensors can discover the exposure of environment to
ultraviolet radiation.
o Touch Sensor:- A touch sensor acts as a variable resistor based on the location
where it is sensed.
 o Proximity Sensor:- A proximity sensor detects the presence of objects that are
placed in close proximity without any point of contact.
45. Why Gas Containers Are Mostly In A Cylindrical Shape?
The ideal shape would be a sphere. The container must have the capacity to withstand the
extremely high pressure of liquefied gas. A spherical shape helps in distributing these forces
uniformly.
46. How Many Types Of Suspensions Are Used In Automobiles?
o McPherson struts
o Leaf spring
o Coil spring
o Torsion beam
o Wishbone
o Air Suspension
47. What Is Dtsi? Why It Is Used In Motor Bikes?
Digital Twin Spark Ignition. This is used for a better fuel combustion in the cylinder head which
helps provide better efficiency and optimum use of fuel.
48. What Is Meant By Gear Ratio?
A gear ratio is a direct measure of ratio of the rotational speeds of two or more interlocking gears.
49. What Is The Percentage Of Carbon Present In Mild Steel , Low Carbon Steel, High Carbon
Steel, Pig Iron?
o Carbon content in Low Carbon Steel is generally 0.05-0.15%.
o Carbon content in Mild Steel is generally 0.16-0.29%. & Density is 7.85 g/cubic cm.
o Carbon content in High Carbon Steel is generally 0.3-1.7%.
o Carbon content is Pig Iron is generally 3.5-4.5%.