Federal Mogul India Production Engineer Interview: Rounds, Questions and Preparation

What the job involves

A production engineer in manufacturing and automobile sectors plans, schedules, and supervises production lines to meet output, quality, and cost targets. They troubleshoot shop-floor issues, improve cycle times, and coordinate with quality, maintenance, and supply chain teams. At companies like Federal Mogul India, the role often involves working on engine components, braking systems, or sealing products in high-volume environments.

Role and Technical Knowledge

1. 1

   What is OEE and how would you calculate it for a production line?

   Define OEE as Availability x Performance x Quality. Explain each factor with a simple example, such as a CNC line making 100 parts per hour.

2. 2

   Explain the difference between accuracy and precision in manufacturing, with an example from automobile parts.

   Accuracy is closeness to target; precision is repeatability. Use a piston diameter example where parts are consistent but off-center.

3. 3

   What are the key steps in setting up a new production line for a high-volume component?

   Cover capacity study, line balancing, machine selection, fixture design, trial runs, and operator training. Mention takt time and cycle time.

4. 4

   How does GD&T help in the production of engine or braking components?

   Explain how GD&T defines form, orientation, and location tolerances, reducing ambiguity in inspection and assembly of critical parts.

Practical Scenarios

1. 5

   Your line is producing parts with a sudden increase in rejection rate. How do you investigate?

   Use a structured approach: contain the issue, check recent changes (material, tool, operator), apply 5 Why or Fishbone, and verify corrective action.

2. 6

   A machine breakdown halts production for 2 hours. What do you do to recover the lost output?

   Prioritize maintenance call, assess buffer stock, adjust schedules, run overtime if needed, and communicate with planning and dispatch.

3. 7

   Operators resist a new standard operating procedure that reduces cycle time. How do you handle it?

   Involve operators early, explain benefits, provide training, and run a pilot. Address concerns about safety or workload.

4. 8

   You notice a safety hazard near a conveyor but production is running. What is your immediate action?

   Stop the line if risk is high, inform safety officer, isolate the hazard, and document. Safety takes priority over output.

Behavioural and HR

1. 9

   Tell me about a time you worked in a team to solve a problem under time pressure.

   Use STAR format. Highlight your specific role, the action taken, and the measurable result, such as reduced downtime or improved yield.

2. 10

   How would you handle a disagreement with a senior operator about a process change?

   Show respect for experience, present data, listen to concerns, and seek a trial-based resolution. Emphasize collaboration over conflict.

3. 11

   Are you comfortable working in shifts, including night shifts, in a plant environment?

   Answer honestly and positively. Mention adaptability and willingness to learn from shop-floor exposure.

4. 12

   Why do you want to join the manufacturing sector, and what do you know about our company's products?

   Link your interest to hands-on problem-solving and continuous improvement. Research the company's key products like engine bearings or brake pads.

Process Improvement and Quality

1. 13

   What is Kaizen and how have you applied it in a project or internship?

   Define Kaizen as continuous small improvements. Give a concrete example, such as reducing setup time or eliminating a wasted motion.

2. 14

   How would you use SPC to control a critical dimension on a machined part?

   Explain control charts, setting UCL and LCL, monitoring trends, and taking action when points go out of control. Mention Cp and Cpk.

3. 15

   What is the difference between preventive and predictive maintenance?

   Preventive is time-based; predictive is condition-based using sensors. Relate to reducing unplanned downtime on a production line.

4. 16

   How do you calculate takt time and why is it important?

   Takt time = available production time / customer demand. Explain how it sets the pace for line balancing and meeting delivery schedules.