10 Common Manufacturing Process Questions Asked in The Interviews: Theory Series 04

Q1 : What is a manufacturing process? A: A manufacturing process is a series of steps and operations involved in converting raw materials or components into finished products on a large scale.

Q2 : What are the different types of manufacturing processes? A: There are several types of manufacturing processes, including:

1. Casting: It involves pouring molten material into a mold to create a desired shape.
2. Machining: This process uses cutting tools to remove material and shape the final product.
3. Forming: It involves deforming or reshaping materials through processes like bending, rolling, or extrusion.
4. Welding: It joins two or more pieces of material by melting and fusing them together.
5. Assembly: It involves putting together different components to create a finished product.
6. 3D Printing: This additive manufacturing process builds three-dimensional objects by layering materials based on a digital design.

Q3 : What is lean manufacturing? A: Lean manufacturing is a systematic approach that aims to minimize waste and maximize value in the manufacturing process. It focuses on eliminating non-value-added activities, reducing inventory, improving efficiency, and enhancing overall quality.

Q4 : What is Six Sigma in manufacturing? A: Six Sigma is a methodology used in manufacturing to improve the quality of processes and products by identifying and eliminating defects and reducing variability. It employs statistical analysis and problem-solving techniques to achieve a high level of quality control.

Q 5: What is Just-in-Time (JIT) manufacturing? A: Just-in-Time (JIT) manufacturing is an inventory management strategy that aims to produce and deliver products exactly when needed, minimizing inventory and associated costs. It helps reduce waste, lead times, and storage requirements by synchronizing production with customer demand.

Q 6: What is Total Quality Management (TQM)? A: Total Quality Management (TQM) is a management philosophy that focuses on continuously improving the quality of products, processes, and services. It involves all employees in the organization, emphasizing customer satisfaction, employee involvement, and data-driven decision-making.

Q7: What is Computer Numerical Control (CNC) machining? A: Computer Numerical Control (CNC) machining is a manufacturing process that uses computerized control systems to operate machine tools. It allows for precise and automated control of various machining operations, such as cutting, drilling, milling, and turning.

Q8  What is the difference between batch production and mass production? A: Batch production involves producing a limited quantity of identical products in a specific sequence, while mass production refers to the continuous production of large quantities of standardized products. Batch production allows for more flexibility and customization, while mass production focuses on efficiency and cost reduction.

Q9: What is Quality Assurance (QA) in manufacturing? A: Quality Assurance (QA) in manufacturing refers to the systematic processes and activities implemented to ensure that products meet specified quality requirements. It involves inspecting, testing, and monitoring products throughout the manufacturing process to identify and rectify any defects or deviations from quality standards.

Q10: What is a Bill of Materials (BOM)? A: A Bill of Materials (BOM) is a comprehensive list of all the raw materials, components, sub-assemblies, and quantities required to manufacture a specific product. It provides a structured outline for production planning, inventory management, and cost estimation.

Q11: What are the casting defects?

Casting defects are common occurrences in the casting process that result in imperfections or flaws in the final cast product. Some common casting defects include:

1.     Porosity: This defect appears as small voids or bubbles in the cast metal caused by trapped air or gases. It weakens the structure and reduces the material's integrity.

2.     Shrinkage: Shrinkage defects occur when the casting solidifies and cools, causing uneven cooling and resulting in voids or cavities in the casting. It can lead to dimensional inaccuracies and reduced mechanical properties.

3.     Inclusions: Inclusions are foreign materials, such as sand, slag, or oxides, that become trapped in the casting during the pouring process. They can weaken the structure and affect the mechanical properties.

4.     Cold shuts: Cold shuts occur when two streams of molten metal do not fuse properly during the filling process, leading to a visible line or seam in the casting. It weakens the casting and affects its integrity.

5.     Misruns: Misruns happen when the molten metal fails to completely fill the mold cavity, resulting in an incomplete casting. It can be caused by insufficient pouring temperature or inadequate gating system design.

6.     Hot tears: Hot tears are cracks or fractures that occur during the cooling and solidification of the casting due to internal stresses. They are typically caused by inadequate mold rigidity or uneven cooling rates.

7.     Sand wash: Sand wash refers to the surface defect where the mold material is eroded or washed away by the molten metal, leaving a rough or uneven surface finish on the casting.

8.     Surface roughness: Surface roughness defects occur when the mold surface is not smooth or when the casting is not properly cleaned, resulting in an uneven or rough surface finish.

9.     Warpage: Warpage is the distortion or deformation of the casting from its intended shape. It can occur due to uneven cooling, improper mold design, or residual stresses in the casting.

10.  Flash: Flash is an excess metal or thin fins that are formed at the parting line of the mold due to excessive molten metal or mold misalignment. It needs to be removed to achieve the desired casting shape.

Read the author's book to support the blog. You will know the Engineering world in a better manner.