Electrical interview question

1- Draw the dol circut digram ?

2- How to decide conducter size?
Ans-1) Gathering data about the cable, its installation conditions, the
load that it will carry, etc
2) Determine the minimum cable size based on continuous current
carrying capacity
3) Determine the minimum cable size based on voltage drop
considerations
4) Determine the minimum cable size based on short circuit
temperature rise
5) Determine the minimum cable size based on earth fault loop
impedance
6) Select the cable based on the highest of the sizes calculated in
step 2, 3, 4 and 5

3- How to decided conucter size in underground

4- What is degree of protection
5- How to decide or check panel installation
Ans-electrical\transformer.docx
6- What is check list for transformaer installation
Ans-
7- What is preventive maintence of transformer
8- What is check list for heavy motor installation
9- Type of earthing
ANS--
10- What is cable scheduling
11- List of generater protection
12- List of transformer protection
13- Why transformer oil used
14-
15- Which oil used in transformer
Transformer oil's primary functions are to insulate and cool a transformer. It must
therefore have high dielectric strength, thermal conductivity, and chemical stability, and
must keep these properties when held at high temperatures for extended

Polychlorinated biphenyls (PCBs)

16- What type of earthing

17- How you protect transformer
18- Number of protection for transfromer ,alternater
19- Type of protection for turbine
20- How to calculate size of motor
21- How to calculate size of transformer
22- Circuit digram symbol
23- Description of motor used in your plant HT ,compressure,
24- Type of motor starter
25- Which motor starter is used for which size motor
26- What is class of motor
27- TELL ME name of transformer protection device name or model which used
in organisation
28- Why hollow pin use in pluck –electric?
29- Tel me generator protection device name
30- MCCB /MCB curve you know what is this?
31- Short sircuit calculation formula
32- What is part of PLC
33- At which input you will applied proximity sensor output
34- What is series test and parallel test and circuit digram
35- Circuit digram of tublight and ac
36- Tell me transformer name plate data details
37- What parameter is important to buy acb
38- What is megger test?
39- What should be consider before energising transformer ?
40- What is diffrernce in power and energy
41- What is difference between relay and MCB cirbreker.
42- Why earting point is thicker then other in electric pluck
43- What is difference between contactor and relay.
44- What is different between energy management system and power
management system
45- What is active power and reactive power
46- What is resistance and what is resistore ?
47- What is power factor
48- What is voltage
49- What is currnet
50- What is principal of transformer
51- What is impedance and inductore ?
52- What is capacitor
53- What is capacitance
54- What is inductive, capacitve ,resistive load.
55- Where you applied analogue input and digital output signal device
56- What is Frame size of electrical motor?
57- What are common excitation frequencies.
58- How to know about motor details when name plate is not available?
59- What is temperature rise in motors?
60- How to measure the motor insulation and verify it’s suitability
61- What is Polarisation Index ?
62- What is purpose of polarisation index ?
63- What is Impregnation System ?
64- What is the purpose of starter-(safety ,reduce starting current , increase
starting torque,)
65- How you will check that BUCHHOLZ RELAY is working?
66- Which earthing can run on 3p acb ,and which can run on 4p
circuit breaker
67- Which model of PLC you worked
68- How many number of I/p and o/p are available
69- What are life time of bearing for squirle cage motor?
70- What will you do for motor proper running?
71- What is hot spot temperature rise?
72- What is trip classs of mccb or circuit breaker ?
73- What is frequency ?
waves can be measured by how (number of time )many times waves complete a cycle in a
second.

1- high value will lead more hysteresis and eddy current losses in many
machines.
2- The higher will be the frequency, the more will be the losses and lower
frequencies would cause the size, weight & hence the cost to increase.
Also, more flickers are noticed in lesser frequencies than higher
frequencies.
3- Its only because, too low value will create fluctuation in apparatus like
Bulb starts blinking(persistence of eye is 15 Hz)
4- If you increase the frequency its occurs more heat. Then our transmission
line takes some losses( More heat to melting point)
5- At higher frequencies there would have been more iron losses which
means a lower efficiency and more heat to be removed from the
transformer to prevent damage.
74- what is difference between off load and on load changeover ?
75- What is difference between neutral and earthing ?
76- Which type earthing is used in mountin (pathar area) and what is chemical
earthing ?
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Mechnical interview question

Instrument question

Production question
1. what is KK piller in TPm?
2. tell me 10 tools used in define phase

1-Process Map
2-Project Charter

3--DMAIC WBS(work breakdown structure))—Project Tracking Tool

4-Stakeholder’s Analysis
5--SIPOC (Supplier–Input–Process–Output–Customer) Diagram
6-SWOT (Strength–Weakness–Opportunity–Threat)
7--Affinity Diagram
8--Kano model
9-Critical to Quality (CTQ) Definitions
10--QFD (Quality Function Deployment/Design)

3. tell me 10 tool of measure phase

1-Process Mapping (Detailed Look)

2-- Input and Output Definition (Xs and Ys)
3-Benchmarking
4--Scorecards
5--CTQs—Measurement
6-Cp and Pp Index
7-- Measurement Systems Analysis (MSA)
8--Sigma Calculations
9-- Failure Mode and Effects Analysis (FMEA)
10--Data Collection Plan

PID-BSF-MCCS

4. Tell me tools name used in Improvement phase of DMIAC

1. Project Plan
2. Failure Mode Effects Analysis (FMEA)
3. Brainstorming
4. the Pugh matrix, which is a decision matrix.
5. Decision Matrix
6. Pilot
7. Poka-Yoke
5. Tell me tools name used in Analysis phase of DMIAC

APL-75-SSD

1. 7QC tools
2. 5-WHY
3. Analysis of Variance (ANOVA)
4. Probability Models/Distributions
5. Linear Regression
6. Statistical Process Control (SPC)
 7. Stem-and-Leaf Diagram
8. Design of Experiment

6.

Tell me tools name used in control phase of DMIAC

RSS-CTC-5

1. ROI Formula
2. Sigma Calculations
3. Control Charts
4. Transition Plan Template
5. Sustainability
6. Close-Out Activities
7. 5S

7. what is 5 law of lean manufacturing/six sigma?

1-law of market
2- law of flexibility
3-law of focus
4- law of velocity
5- law of complexibility

8. What are the basic thing which every production manager know/project manager
1-Integration Management
2-Scope Management
3-Time Management
4-Cost Management
5-Quality Management
6-Human Resource Management
7-Communications Management
8-Risk Management
9-Project Procurement Management

PHICR -S-CTQ
9. What is TOPS or 8D?
step 0-- plan
Step 1—Establish the Team/Designate a team

Step 2—Describe the Problem

Step 3—Develop an Interim Containment Action

Step 4—Define/Verify Root Cause

Step 5—Choose/Verify Permanent Corrective Action/Determine permanent corrective actions

Step 6—Implement/Validate Permanent Corrective Action/ Deploy the action plan

Step 7—Prevent Recurrence/Document to avoid renewal of the problem

Step 8—Recognize the Team /congragulation to team

10.
What is Eight Disciplines of Problem Solving (8D)
The 8D problem solving process is a detailed, team oriented approach to solving critical problems in
the production process. The goals of this method are to find the root cause of a problem, develop
containment actions to protect customers and take corrective action to prevent similar problems in the
future

11.
Why Apply Eight Disciplines of Problem Solving (8D)
because it offers your engineering team a consistent, easy-to-learn and thorough approach to
solving whatever problems might arise at various stages in your production process
 Improved team oriented problem solving skills rather than reliance on the individual
 Increased familiarity with a structure for problem solving
 Creation and expansion of a database of past failures and lessons learned to prevent problems in
the future
 Better understanding of how to use basic statistical tools required for problem solving

12.
When to Apply Eight Disciplines of Problem Solving
(8D)
The 8D problem solving process is typically required when:
 Safety or Regulatory issues has been discovered
 Customer complaints are received
 Warranty Concerns have indicated greater-than-expected failure rates
 Internal rejects, waste, scrap, poor performance or test failures are present at unacceptable levels

13.
What is Failure Mode and Effects Analysis (FMEA)
Failure Mode and Effects Analysis (FMEA) is a structured approach to discovering potential failures
that may exist within the design of a product or proces
14.
Why Perform Failure Mode and Effects Analysis
(FMEA)
FMEA is one of many tools used to discover failure at its earliest possible point in product or process
design. Discovering a failure early in Product Development (PD) using FMEA provides the benefits of:
 Multiple choices for Mitigating the Risk
 Higher capability of Verification and Validation of changes
 Collaboration between design of the product and process
 Improved Design for Manufacturing and Assembly (DFM/A)
 Lower cost solutions
 Legacy, Tribal Knowledge, and Standard Work utilization

15.
When to Perform Failure Mode and Effects Analysis
(FMEA)
There are several times at which it makes sense to perform a Failure Mode and Effects Analysis:
 When you are designing a new product, process or service
 When you are planning on performing an existing process in a different way
 When you have a quality improvement goal for a specific process
 When you need to understand and improve the failures of a process

16. What is kano model ?

suggests that customer preferences are divided into categories that include delighters, satisfiers, and
dissatisfiers,
it divided into these five themes: ,1-Attractive,2-One-Dimensional,3-Must-Be,4-Indifferent ,5-Reverse

17. What is Affinity Diagram ?

organizes a large number of ideas into their natural relationships. The first step is simple brainstorming
followed by listing the ideas in categories.

18. What is 7qc tools ?

1- Flow chart
2- Fishbone
3- Control chart
4- Check list
5- Preato chart
6- Histogram chart
7- Scatter digram

19.
What is a Scatter Plot?
A scatter plot is a two-dimensional data visualization that uses dots to represent the values
obtained for two different variables - one plotted along the x-axis and the other plotted along the
y-axis. For example this scatter plot shows the height and weight of a fictitious set of children.
20.
When to Use Scatter Plots
Scatter plots are used when you want to show the relationship between two variables. Scatter
plots are sometimes called correlation plots because they show how two variables are correlated.
In the height and weight example, the chart wasn’t just a simple log of the height and weight of a
set of children,

21. What Is line balancing?

22. Formula of line effieciency?
23. What is TPM and there pillers ?
24. What is 5S , in order ?
25. How you make consistence your production output?
1- By making number of multiskilling employee
2- Motivation of employee and positive work activity to work with team

26. 3- What is Deming’s Seven Deadly Diseases?

27. What is 6w?
5W and 2H (who, what, where, when, why, how, how often)

28. How many type of check list ?

29. What is Quality Planning Road?
30. What is variance in system ?
31. What is shingo prise ?
The mission of the
Shingo Prize is to create excellence in organizations through the application
of universally accepted principles

32. What is immediate goal for wip?

Reduced it as soon as posible
33. What quality for Successful leadership development is linked to leader ?-7

1-An individual’s ability to learn

2-Quality and nature of the leadership development program

3-Genuine support for the leader’s supervisor

 4-Choosing the right projects

5-Choosing the right people

6-Following the right methodology

7-Clearly defining roles and responsibility

34. What is kiazen ?

35. Give me the example when you kaizen implement ?
36. Q-what is objective of TQM?
ANS-- The simple objective of TQM is “Do the right things, right the first time, every time.”

37. What is steam –leafe digram ?

38.
39. What tool used to find out reason of project delay ?
1- Force-field diagrams
2- Lessons-learned evaluations from tollgate meetings
3- Balanced scorecards showing the improvement rate of the key performance indicators
4- Creative brainstorming about delays, which were used to create a cause and effect
diagram
CRT- current reality tree
40. What is DFMA
ANs--DFMA stands for Design for Manufacture and Assembly. DFMA is the combination of two
methodologies; Design for Manufacture, which means the design for ease of manufacture of the parts
that will form a product, and Design for Assembly, which means the design of the product for ease of
assembly

5- DFMA is also used as a benchmarking tool to study competitors’ products

41. What is integrated product development (IPD)?
42. What is Risk Priority Number (RPN), calculated based on:?

The results are then taken to an even more granular level with the determination of a Risk
Priority Number (RPN), calculated based on:

 Severity of the failure effect (S): A value applied on a scale of 1 (low) to 10 (high)
 Frequency of failure occurrence (O): A value applied on a scale of 1 (infrequent) to 10
(frequent)
 Detectability/Preventability (D): A value assigned on a scale of 1 (very detectable) to 10
(not detectable)
 The formula applied is S x O x D, the product of which is an RPN anywhere from 1 (low risk)
to 1,000 (high risk). Users are then able to define what is acceptable and unacceptable for the
failure being analyzed.

43.
44.
45. What is CRT?
46. What is HohRenSoh rule ?

first advice you get when you start working in a company./

Communicate the progress of the work you have been given by mentioning the problems and results.

47. What is HACCP ?

H azard A nalysis and C ritical C ontrol Panointed/point: / Developed by Pillsbury, NASA

48. What is Haccp principal ?

HACCP is a systematic approach to the identification, evaluation, and control of food safety hazards based
on the following seven principles:

Principle 1: Conduct a hazard analysis.

Principle 2: Determine the critical control points (CCPs).

Principle 3: Establish critical limits.

Principle 4: Establish monitoring procedures.

Principle 5: Establish corrective actions.

Principle 6: Establish verification procedures.

Principle 7: Establish record-keeping and documentation procedures.

49. What is 3M?

50. What is 3G/6G?
51. What is 3K?
52. What is QRQC?
53. What is Fulkerson's Rule

Draw a precedence diagram as follows:

1Prioritize tasks in order of the largest number of following tasks:

2-(b) Prioritize
tasks in order of longest task time. Note that D should be assigned before B, and E
assigned before C due to this tie-breaking rule.]
 Make task assignments to form workstation 1, workstation 2, and so forth until all tasks
are assigned. It is important to meet precedence and cycle time requirements as the
assignments are made.

54. What is GRP?

G roup R esolution of P roblems.

55. What is SQCDME ?

S as security/safety, Q as Quality, C as cost, D as (Deadlines)Timeouts/delevery , ,M as

motivation, E as Environment
SQDC board placed in a process area, to quickly convey how the process is performing
against these 4 categories.

For example, Safety would measure whether the safety measures or metrics were achieved
each day, and marked on the board. Safety metrics might include:

 No near misses
 No safety violations
 No missed work due to injuries
 No unsafe work practices observed
 No safety glasses violations

Through QCDSM they can measure their own performance on a daily or weekly
basis

56. What is CODP ?

Customer order decoupling point

Since the CODP provides a decoupling point between upstream and downstream operations. Quality
planning, control and improvement will focus on maintaining efficient processes for upstream operations,
whereas the product delivered to the customer is the main planning object for post-CODP operations.
(Olhager, 2003, p. 324) Operations upstream the CODP have to successfully provide to the market the right
products in the right quantities at the right cost level at the CODP inventory position. With this in place,
the downstream operations have the prerequisites for providing the marketplace with customized
products in a timely and effective manner. (Olhager, 2010, p. 867)

In the P: D ratio, both ‘P’ and ‘D’ are lengths of time, where ‘P’ represents the production lead-time and ‘D’
represents the delivery lead-time (the time from order to delivery). Based on the ratio of ‘P’ divided by ‘D’
one can determine the amount of planning and production that needs to be based on speculation, and the
amount that can be based on customer orders

The Customer Order Decoupling Point refers to the point in the value chain of mass customization at
which a customer triggers the production activities. All activities before the CODP are drive by a firm's
market research and planning department

57. What is AAI ?

58. What is bell chart ?
When the bell chart is perfectly shaped, not leaning to one side or the other, the process is
said to be in control or stable (Figure 6.11).
59. What is control chart ?
Control charts are used to ensure that the process is in control and to monitor process variation on a
continuous basis.

60.
What is Corrective Action Preventive Action (CAPA)
Corrective Action Preventive Action (CAPA) is a process which investigates and solves problems, identifies
causes, takes corrective action and prevents recurrence of the root causes. The ultimate purpose of CAPA is
to assure the problem can never be experienced again.
61.
Why Implement Corrective Action Preventive Action
(CAPA)
62. What is goal of TPM?
goal is to maximize equipment use and effectiveness.
63. When TPM used in organistion ?

When machine breakdown time is high and no one ready to resoponsibilty and know data
is availabe
64. What is the difference between a bar chart and a histogram?

Bar chart---- in bar chart X-axis data use for name , y –axis used data ,statics
Histogram ===in this both X and Y axix used data , measure and value
histogram is only used to plot the frequency of score occurrences in a continuous data set t

65. How do you construct a histogram from a continuous variable?

To construct a histogram from a continuous variable you first need to split the data into intervals,
called bins. In the example above, age has been split into bins, with each bin representing a 10-
year period starting at 20 years. Each bin contains the number of occurrences of scores in the data
set that are contained within that bin. For the above data set, the frequencies in each bin have
been tabulated along with the scores that contributed to the frequency in each bin (see below):
66. Draw a histo gram for any case

Dent 1-4 4- 8-12 12-

length mm 8mm mm 16mm
Number 20 26 27 10
of
frequency

67. What is DOE?

Design of Experiments (DOE) is a statistical tool available to engineers that can be used to evaluate single
changes or multiple changes to a process at once and predict the resulting change to the output of the process.

Design of Experiments (DOE) is a branch of applied statistics focused on using the scientific method for
planning, conducting, analyzing and interpreting data from controlled tests or experiments.

68.
Why Utilize Design of Experiments (DOE)
1- To find out . A robust Design of Experiments can save project time and uncover hidden issues
in the process
2- By performing a multi-factorial or “full-factorial” experiment, DOE can reveal critical
interactions that are often missed when performing a single or “fractional factorial” experiment.

69.
When to Utilize Design of Experiments (DOE)
1- Experimental design or Design of Experiments can be used during a New Product / Process
Introduction (NPI) project or during a Kaizen or process improvement exercise.
2- During the “Analyze” phase of a project, DOE can be used to help identify the Root Cause of a problem
During the “Improve” phase of a project, DOE can be used in the development of a predictive
equation, enabling the performance of what-if analysis.
70. What is Boundary Diagram ?

An FMEA Block diagram (or Boundary diagram) is a visual depiction of the entire system or design to
clearly show the boundaries of the FMEA (i.e., what is included and not included), the interfaces
between the items and other information that can help to depict the scope of the analysis.
3-
71.
What is Fault Tree Analysis (FTA)
Fault Tree Analysis is a top-down, deductive analysis which visually depicts a failure path or failure chain.
FTA follows the concept of Boolean logic, which permits the creation of a series of statements based on True
 / False. When linked in a chain, these statements form a logic diagram of failure. Events are arranged in
sequences of series relationships (the “ors”) or parallel relationships (the “ands”). Results for each event are
presented in a tree-like diagram using logic symbols to show dependencies among events.
72.
Why Perform Fault Tree Analysis (FTA)
FTA depicts the risk-based path to a root cause or Base-level event. The identified risks drive actions
which are intended to mitigate the risk prior to program launch. Alternatively, when investigating a
failure, the chain of events depicted by FTA allows the problem solver to see the events leading to a
root cause(s) or Base-level event. The Fault Tree Analysis is applied when:
 A Hazard Analysis previously indicated a safety concern
 There is a new design with new content
 There is a current design with modifications, which may include changes due to past failure

73.
How to Perform Fault Tree Analysis (FTA)
As previously mentioned, the FTA is a logical breakdown from the Top-level undesired event, cascaded to the
Base-level event (root cause). Each path has a probability assigned
he 5 basic steps to perform a Fault Tree Analysis are as follows:
1. Identify the Hazard
2. Obtain Understanding of the System Being Analyzed
3. Create the Fault Tree
4. Identify the Cut Sets
5. Mitigate the Risk

74.
What is Weibull Analysis
Weibull Analysis is a methodology used for performing life data analysis. Life data is the result of
measurements of a product’s life. Weibull Analysis is an effective method of determining reliability
characteristics and trends of a population using a relatively small sample size of field or laboratory test
data. Depending upon the product or industry, product life data is calculated in hours, miles, number of
cycles

75. Why Perform Weibull Analysis

Most companies in business today monitor warranty costs and product failure rates. The goal is to reduce
warranty costs and possible loss of brand equity. In addition, information gathered using a Weibull Analysis
allows the manufacturer to plan for any known costs or set the proper warranty terms
76. What is production ?
which is concerned with the transformation of a range of inputs into the required outputs (products) having the
requisite quality level.
77. How many type of production you know ?

78. What is advantage and disadvantage of each ?

79. What is role and reposibility and target of production Manager?
E.S. Buffa defines production management as, “Production management deals with
decision making related to production processes so that the resulting goods or services are
produced according to specifications, in the amount and by the schedule demanded and
out of minimum cost.
80. What is Objectives of Production Management ?
1. RIGHT QUALITY
2. RIGHT QUANTITY
3. RIGHT TIME
RIGHT MANUFACTURING COST
81. What is LOCATION MODELS to choose new plant ? tell me name of that
Various models are available which help to identify the ideal location. Some of the popular models
are:
1. Factor rating method
2. Weighted factor rating method
3. Load-distance method
4. Centre of gravity method
5. Break even analysis

82. What is Objectives of Plant Layout?

The objectives of plant layout are:

1. Streamline the flow of materials through the plant.
2. Facilitate the manufacturing process.
3. Maintain high turnover of in-process inventory.
4. Minimise materials handling and cost.
5. Effective utilisation of men, equipment and space.
6. Make effective utilisation of cubic space.
7. Flexibility of manufacturing operations and arrangements.
8. Provide for employee convenience, safety and comfort.
9. Minimize investment in equipment.
10. Minimize overall production time.
11. Maintain flexibility of arrangement and operation.
12. Facilitate the organizational structure.
83. What is Principles of Plant Layout ?

Principle of integration: A good layout is one that integrates men, materials, machines
and supporting services and others in order to get the optimum utilisation of resources and
maximum effectiveness.
2. Principle of minimum distance: This principle is concerned with the minimum travel
(or movement) of man and materials. The facilities should be arranged such that, the total
distance travelled by the men and materials should be minimum and as far as possible straight
line movement should be preferred.
3. Principle of cubic space utilisation: The good layout is one that utilise both horizontal
and vertical space. It is not only enough if only the floor space is utilised optimally but the third
dimension, i.e., the height is also to be utilised effectively.
4. Principle of flow: A good layout is one that makes the materials to move in forward
direction towards the completion stage, i.e., there should not be any backtracking.
5. Principle of maximum flexibility: The good layout is one that can be altered without
much cost and time, i.e., future requirements should be taken into account while designing the
present layout.
6. Principle of safety, security and satisfaction: A good layout is one that gives due
consideration to workers safety and satisfaction and safeguards the plant and machinery against
fire, theft, etc.
7. Principle of minimum handling: A good layout is one that reduces the material handling
to the minimum
84. How many type of plant layout ?
Layouts can be classified into the following five categories:
1. Process layout
2. Product layout
3. Combination layout
4. Fixed position layout
5. Group layout

85. What is line balancing formula ,efficiency ?

86. What is flow matrix ?
The amounts and/or costs of flows among work centres are usually presented using a flow
matrix, a flow-cost matrix, or a proximity chart.
87. Why Material handling is important in production system?
Material handling does not add
any value to the product but adds to the cost of the product and hence it will cost the customer
more. So the handling should be kept at minimum. Material handling in Indian industries accounts
for nearly 40% of the cost of production. Out of the total time spent for manufacturing a product,
20% of the time is utilised for actual processing on them while the remaining 80% of the time
is spent in moving from one place to another, waiting for the processing. Poor material handling
may result in delays leading to idling of equipment.
88. What is Materials Handling Labour (MHL) ratio. And DLHL ?

89. Tell me MATERIAL HANDING EQUIPMENTS name ?

(a) Fixed path equipments, and (b) Variable path equipments.
90. What you under stand by material Management ?
91. What is material planning explosion tech

92.
What is purchase Parameter , what should keep in mind
93. What is Purchasing Procedure ? and there order

94. How to decided which vender is good ?

suggested following methods for evaluating the performance of past suppliers
 1. The categorical plan:
2. The weighted-point method:
3. The cost-ratio plan:
timely delivery. It assigns the relative weight to each of these factors as under:
Quality ……… 50 points
Price ……… 30 points
Timely delivery ……… 20 points
95. Tell me formula for The weighted-point method:

96. What is The different techniques of inventory control are ?

the concern of the management to have a proper control over its ordering, procurement,
maintenance and consumption. The control can be for order quality and order frequency.
The different techniques of inventory control are:
(1) ABC analysis,
The most widely used method of inventory control is known as ABC analysis. In this technique,
the total inventory is categorised into three sub-heads and then proper exercise is exercised for
Once ABC classification has been achieved, the policy control can be formulated as follows:
A-Item: Very tight control, the items being of high value. The control need be exercised at
higher level of authority.
B-Item: Moderate control, the items being of moderate value. The control need be exercised
at middle level of authority.
C-Item: The items being of low value, the control can be exercised at gross root level of
authority, i.e., by respective user department managers.
2. HML analysis: In this analysis, the classification of existing inventory is based on unit
price of the items. They are classified as high price, medium price and low cost items.
3. VED analysis: (Vital, Essential and Desirable ) ,In this analysis, the classification of existing
inventory is based on criticality
of the items. They are classified as vital, essential and desirable items. It is mainly used in spare
parts inventory.
4. FSN analysis: In this analysis, the classification of existing inventory is based consumption
of the items. They are classified as fast moving, slow moving and non-moving items.
5. SDE analysis: In this analysis, the classification of existing inventory is based on the
items. (scarce items, difficult items, easily available)
6. GOLF analysis: In this analysis, the classification of existing inventory is based sources
of the items. They are classified as Government supply, ordinarily available, local availability and
foreign source of supply items.
7. SOS analysis: In this analysis, the classification of existing inventory is based nature of
supply of items. They are classified as seasonal and off-seasonal items.
For effective inventory control, combination of the techniques of ABC with VED or ABC
with HML or VED with HML analysis is practically used.

97. What is benefit of jIT

4.11.2 Benefits of JIT

The most significant benefit is to improve the responsiveness of the firm to the changes in the
market place thus providing an advantage in competition. Following are the benefits of JIT:
1. Product cost—is greatly reduced due to reduction of manufacturing cycle time, reduction
of waste and inventories and elimination of non-value added operation.
2. Quality—is improved because of continuous quality improvement programmes.
3. Design—Due to fast response to engineering change, alternative designs can be quickly
brought on the shop floor.
4. Productivity improvement.
5. Higher production system flexibility.
6. Administrative and ease and simplicity.

98. What is Priority Decision Rules for production ?

99. What is PERT/CPM network model: ?
100. What is control process for quality explain it ?
The control process involves a universal sequence of steps as follows:
1. Choose the control object
2. Choose a unit of measure
3. Set the standard value
4. Choose a sensing device which can measure
5. Measure actual performance
6. Interpret the difference between actual and standard
7. Taking action.
101. How many type of inspection is done in your organisation ?
Types of inspection are:
1. Floor inspection
2. Centralized inspection
3. Combined inspection
4. Functional inspection
5. First piece inspection
6. Pilot piece inspection
7. Final inspection
102. What is Methods of Inspection?
There are two methods of inspection. They are: 100% inspection and sampling inspection
103. What is Objectives of Quality Control ?
104. What is OPERATING CHARACTERISTIC CURVE (O.C. CURVE)?
Refert to pdf book –new age pub
105. What is Quality circles,?
According to Juran, quality circle defined as “a group of work force level people, usually
from within one department, who volunteer to meet weekly (on company time) to address quality
problems that occur within their department.”
106. What is Benefits of QC?

1. Quality Circles Effect on Individual Characteristics

(a) Quality circles enable the individual to improve personal capabilities—group participation
and learning specific problem-solving tools.
(b) Quality circles increase the individual’s self-respect.
(c) Quality circles help worker change certain personality characteristics—shy person become
as active.
2. Quality Circles Effect on Individuals Relations with Other
(a) Quality circles increase the respect of the supervisor for the worker.
(b) Quality circles increase workers understanding of the difficulties faced by supervisors—
problem selection, solving and implementations.
(c) Quality circle increase management’s respect for worker.
3. Quality Circles Effect on Workers and Their Attributes
(a) Quality circles change some workers negative attitudes.
 (b) Quality circle reduces conflict stemming from the working environment.
(c) Quality circles help workers to understand better the reasons while many problems
solved quickly.

107. What is Steps or Procedure Involved in Methods Study?

108. What is symbole for flow chart ?

109. What is Simultaneous motion cycle chart (SIMO chart) ?

SIMO” stands for simultaneous-Motion Cycle chart. It is one of micro

motion study devised by Gilbreth and it presents graphically the
separable steps of each pertinent limb of the operator under study. It is
an extremely detailed left and right hand operation char
 It records simultaneously the different therbligs performed by different
parts of the body of one more operators on a common time scale. The
movements are recorded against time measured in “Winks” (1 wink=
1/2000 minute). These are recorded by a “Wink Counter” positioned in
such a location that it can be seen rotating during filming process.

Construction of “SIMO” Chart:

The SIMO chart for left hand and right hand analysis sheet inform about
the degree of participation of both the hands. The time for each Therblig
recorded on the analysis sheet may be shown to scale by means of a SIMO
chart. Either the SIMO chart may be prepared independently or the chart
may be constructed from the data available on the analysis sheet.

110. What is benefite and average savings resultant from initiation of a functional predictive maintenance
program ?

111. What is MAINTENANCE SCHEDULE TECHNIQUES?

Different types of schedules are made suiting the respective job plans and different techniques
are used for making and following those schedules. The first step of all scheduling is to break
the job into small measurable elements, called activities and to arrange them in logical sequences
considering the preceding, concurrent and succeeding activities so that a succeeding activity
should follow preceding activities and concurrent activities can start together.
Arranging these activities in different fashion makes different types of schedules. They are
as follows:
1. Weekly general schedule is made to provide weeks worth of work for each employee
in an area.
2. Daily schedule is developed to provide a day’s work for each maintenance employee
of the area.
3. Gantt charts are used to represent the timings of tasks required to complete a project.
4. Bar charts used for technical analysis which represents the relative magnitude of the
values.
5. PERT/CPM are used to find the time required for completion of the job and helps in
the allocation of resources.
112.

113. What is X-bar and r-bar chart?

It is a control chart where is X-bar is (average of sample –taken at one time like 5 sample
pice) draw a graph betwwn upper and lower limit , number of time sample ,100 time

Where R chart is draw over range of sample between upper and lower limit
114. What is P chatrt and how deffer from X bar chart

X-r xhart used for messurment control

P- for defectrd quality pice (number of iteam)
115. What is pugh Matrix ?

The Pugh matrix helps determine which items or potential solutions are more important or
‘better’ than others. It is employed after capturing voice of the customer (VOC).

It is a scoring matrix used for concept selection in which options are assigned scores relative
to criteria. The selection is made based on the consolidated scores. Before starting a detailed
design, there are many options – this tool helps with selecting the best option.

This tool is also known as a criteria-based matrix.

116. What is ANOVA

Dependent: Productivity (average number of quality documents produced per hour)

Independent:

1. Age (Under 30, 30-50 years old, over 50)

2. Job experience in company (less than 5 years, 5-10 years, over 10 years)
3. Previous related work experience or education (no or yes)
4. Education Level (no high school degree, high school educated, college educated)
In addition to determining which of the 4 variables influence the productivity, it can also
identify if any of the variables interact with each other, creating a more complicated
relationship. An interaction in this example might be where previous related work experience
 does not matter for workers with over 10 years experience in the company, but makes a big
difference for workers who are under 30 years old and with the company less than 5 years. The
impact on productivity changes when you look at the groups of another variable (it’s not
consistent across the board).

117. what is 3C concept of industry ?

The 3Cs model points out that a strategist should focus on three key factors for success. In the construction
of a business strategy, three main elements must be taken into account:

1. The Company
2. The Customers
3. The Competitors
4. Collaborators
5. Context

There is also a new 3 Cs model emerging which centers on sustainability. This model is:

1. Capability
2. Consistency
3. Cultivation

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135.

Sunwoda industry
1.
Which model you work .?
BLP-673(3300mah) ,615(2200mah),631(2700mah)
MI-E7s,E7,C3b,C3c,D1,
Vivo-BE-6,BE-5,BE-8,
2.
What is difference between lithium ion and lithium polymer battery ?
lithium ion lithium polymer battery
Lithium Ion Batteries have high lithium-polymer batteries are very
energy-densities and cost less lightweight
than lithium-polymer batteries.
do not require priming when first
used and have a low self-
discharge.
, lithium-ion batteries do suffer
from aging – even when not in
use.
 The chemical construction of this battery  Can be made in a variety of shapes.

limits it to a rectangular shape.

Higher chance of lekage Low chance of lekage

Long life span Short life span of charge battery
lack of what’s called the memory effect
(when batteries become harder to charge
over time)
Can catch fire They are also lightweight,
Lithium ion battery uses liquid lithium lithium polymer use solid or gelatin
ion as electrolyte like polymers as electrolyte.
while Li-ion has a carbon cathode and A Li-Po battery has a polymer cathode
a liquid electrolyte and a solid electrolyte
Lithium-ion batteries are made with the liquid electrolyte providing a
conductive medium.
of different compartments
which all generate power.
Each compartment (cell) is
 made up of a positive
electrode, a negative
electrode,
3.
What you mean by aging?

Batteries with graphite anodes suffer their first significant loss of capacity during the initial charging
cycle, the formation step. A battery loses up to ten percent of its capacity in the process. Each
additional charge-discharge cycle reduces storage capacity further, if only insignificantly. Capacity is
also lost through the mere storage of batteries - especially above room temperature.
Physics has come up with a number of ideas about the nature of these aging effects, but no one has
yet found the definitive explanation for them. TUM scientists at the Department of Technical
Electrochemistry and from the FRM II have now come a good deal closer to closing this knowledge gap

4.
What is pulling strength of welding ?
Negetiv---1.5kg , positive =0.5kg
5.
What is level of power during welding.? And how many type of leaer welding
0.05
(a-Solid state laser--G laser outputs between 0.04–6,000 W---- wavelengths on the order of
1 micrometer, )

(Gas laser---- wavelength of the CO2 gas laser beam is 10.6 μm, d----, reaching 25 kW))

,
6.
What is benefit of lesser welding ?
1-high power density (on the order of 1 MW/cm ) 2

2-small heat-affected zones

3-high heating and cooling rates.
4-spot size of the laser can vary between 0.2 mm and 13 mm,
5- The depth of penetration is proportional to the amount of power supplied, but is also dependent on
the location of the focal point: penetration is maximized when the focal point is slightly below the
surface of the workpiece
7.
What is different between lbw and ebw( electron beam
welding)?
Some of the advantages of LBW in comparison to EBW are as follows:
- the laser beam can be transmitted through air rather than requiring a vacuum
- the process is easily automated with robotic machinery
- x-rays are not generated
- LBW results in higher quality welds[citation needed]

8.
What is focus distance in leasser welding?
492 mm
9.
Tell me tape name which are used in assembly
10.
Tell me raw material name ?
11.
What is PI (
Polyimide (PI) Adhesive Tapes

)film tape?
12.
What is PET tapeS
13.
What is material used in making fixtureS
14.
Which ink is used in printing and chemical in printing
15.
What is halogen free of ROHS?
16.
Tell me technical point which you test during functional test?

OCV 3.68—3.78 Open-circuit voltageThere is

no external load connected. No
external electric current flows
between the terminals.
R1(K ohm) 50--------85
DSG-voltage 0.01-------0.48
DSG -current 2.95-----3.05
DOT(mS) 11.2-------20.8 Discharge over time
DOC(A) 6--------10 discharge over current (DOC)
COC charge over current (COC).
discharge short circuit (DSC),
Negative temperature coefficient--NTC

CHG-volt
CHG-current
ST
IR(mili ohm) 50--------75
Ocv2 3.50--------3.68
17.
Tell me the name of documentation which you used in daily basis
18.
How many line in your organigation
16 line physical by infrastructure ,
20 line man power available by day night
19.
How many automatic and how many manual ?
6 manual and 10 semi automatic
20.
How many you product manufacture ?
21.
What is insulation level of tape and addehsivness of tape?
22.
What is addehesive test ?
23.
What is parameter for lekage test of battery ?

24.
Why litium is used of develoed in battery not other ?
Lithium is the lightest of all metals, has the greatest electrochemical potential and provides
the largest specific energy per weight. Rechargeable batteries with lithium metal on the
anode could provide extraordinarily high energy densities;
25.
Can you detail the structure of lithium battery ?
Ans—
 Most Li-ion batteries share a similar design consisting of a metal oxide positive electrode
(cathode) that is coated onto an aluminum current collector, a negative electrode (anode)
made from carbon/graphite coated on a copper current collector, a separator and
electrolyte made of lithium salt in an organic solvent. Table 3 summarizes the advantages
and limitations of Li-ion.

Advantages High specific energy and high load capabilities with Power Cells

Long cycle and extend shelf-life; maintenance-free

High capacity, low internal resistance, good coulombic efficiency

Simple charge algorithm and reasonably short charge times

Low self-discharge (less than half that of NiCd and NiMH)

Limitations Requires protection circuit to prevent thermal runaway if stressed

Degrades at high temperature and when stored at high voltage

No rapid charge possible at freezing temperatures (<0°C, <32°F)

Transportation regulations required when shipping in larger quantities

26.
What you know about latest development of lithium battery

27. Large battery systems for ESS, UPS, marine vessels and traction use mostly large format pouch cells stacked with light
pressure to prolong longevity and prevent delamination
28.
A small Li-ion fire can be handled like any other combustible fire. For best result use a foam extinguisher, CO 2, ABC dry
 chemical, powdered graphite, copper powder or soda (sodium carbonate). If the fire occurs in an airplane cabin, the FAA
instructs flight attendants to use water or soda pop. Water-based products are most readily available and are
appropriate since Li-ion contains very little lithium metal that reacts with water. Water also cools the adjacent area and
prevents the fire from spreading. Research laboratories and factories also use water to extinguish Li-ion battery fires.
29. Li-ion and lead acid batteries cannot be fully discharged and must be stored with a remaining charge. While nickel-
based batteries can be stored in a fully discharged state with no apparent side effect, Li-ion must not dip below 2V/cell
for any length of time.
30. Only use a Class D fire extinguisher for lithium-metal fires because of the reaction of water with lithium. (Li-ion contains
little lithium metal reacting with water.)
31. Lithium batteries are completely empty when discharged to 2.5 V/cell. Discharging a
lithium cell this low is stressful to the cell and reduces cell lifetime. A good battery
protection circuit will also provide over-discharge protection.
32.
33.
What is your rejection ratio?
0.2 %===for battery and pcm
0.4%====for consumbel material
34.
What is break down ratio in your organistaion
Quality===0.06 %(for costely) ,0.25 for (cheaper iteam)
Break down==20 minutes
Small stop ====15-20 minutes
35.
How to tackle idel state problem in your design and how you justifiy
1- I use as learning station for new employee
2- If possibilite I will hand over some extra work ,to reduce subordinate
work
36. Pressure by machine to lift battery 3-6 kpa , 300-380 kpa for lekage test machine
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72.

Job responsibility –production

1. 1-manpower and discipline control
2. Production UPH supervision and improvement
3. Wastge obesravation and controle
4. Supervision of 5S and improvement
5. Cross check our real time documentation and their validity
6. Report make monthely and weekly , and comparision wit last month and week ,try to look loophole and
improvement
7. Do monthly and weekly inventory observe in data deviation,
8. Give feed back for improvememnt in sop , observe way of sop
9. For audit purpose do special focus on visual mangment improvement 5s
10. I have thinking and observation skill for cost reduction purpose with balance scorecard ?
11. I have leadership skill in positive way.
12. I have skill to give feedback for process improvement
 13. I have exp to run organisation from zero to 30 million production
14. I have habbit to work for iso standard paperwork
15.

Job responsibility –electrical –maintenance /project

1. I will plan for maintain ace and decrease breakdown time.
2. I am familiar with electrical standard
3. I have skill to implement TPM to improve OEE.
4. I have skill to manage PMS and,EMS.
5. I will complete the project in time period with balnce soce card.
6. I wii focus on safety standard.
7. I have skill to to convert work responsibility in habbite.
8. I will check out test of equipment at regular interval , there safety device work properly
9.
10.