Kirloskar Oil Engines Quality Engineer Interview: Rounds, Questions and Preparation

What the job involves

A Quality Engineer in manufacturing ensures that products and processes meet defined quality standards and customer requirements. Day to day, they inspect incoming materials, monitor production processes, analyse defects, conduct root cause analysis, and drive continuous improvement using tools like 8D, 5 Why, and SPC. In automobile and engineering firms, they also support PPAP, control plans, and audits to maintain IATF 16949 or ISO 9001 compliance.

Role and Technical Knowledge

1. 1

   What are the 7 QC tools and where would you use each one on a shop floor?

   Name each tool (check sheet, histogram, Pareto chart, cause-and-effect diagram, scatter diagram, control chart, flow chart) and give a one-line use case, such as Pareto for prioritising defects.

2. 2

   Explain the 8D methodology. How is it different from a simple corrective action?

   List the 8 disciplines (D1 to D8) and highlight that 8D includes root cause analysis, permanent corrective action, and prevention, not just fixing the symptom.

3. 3

   What is SPC and how do you interpret a control chart?

   Define SPC as using statistical methods to monitor and control a process. Mention control limits, common vs special cause variation, and rules like a point outside limits or seven points trending.

4. 4

   What is the difference between accuracy and precision? How does MSA help?

   Accuracy is closeness to true value, precision is repeatability. MSA studies like Gage R&R quantify measurement variation and ensure the gauge is suitable for the tolerance.

Practical Scenarios

1. 5

   A customer reports a leak from an engine oil seal. How would you investigate and contain the issue?

   Start with containment (quarantine stock, inform customer), then use 5 Why or fishbone to find root cause (seal damage, assembly force, surface finish), implement corrective action, and verify effectiveness.

2. 6

   During an audit, you find that a control plan is not being followed on the line. What do you do?

   Do not ignore it. Record the nonconformance, inform the supervisor, retrain operators if needed, and update the control plan if it is impractical. Follow up with a corrective action.

3. 7

   You have to reduce rejection of a machined component from 5% to 1%. What steps will you take?

   Collect data, use Pareto to find the top defect, do a fishbone for causes, run a DOE or trial, standardise the fix, and monitor with SPC. Mention cost-benefit if possible.

4. 8

   How would you decide the sample size for incoming inspection of a critical part?

   Refer to sampling plans like IS 2500 or ANSI/ASQ Z1.4, consider AQL, lot size, and criticality. For critical characteristics, 100% inspection or tighter AQL may be needed.

Manufacturing and Process Fundamentals

1. 9

   What is PPAP and why is it important in automotive manufacturing?

   PPAP (Production Part Approval Process) ensures the supplier's process can consistently meet requirements. List key elements like design records, PFMEA, control plan, MSA, and sample parts.

2. 10

   Explain the difference between a defect and a nonconformity. Give an example.

   A defect is a departure from a specification that may affect function; a nonconformity is any failure to meet a requirement. Example: a scratch on a non-critical surface is a nonconformity but not a functional defect.

3. 11

   What is the purpose of a PFMEA? How does it link to the control plan?

   PFMEA identifies potential failure modes, their severity, occurrence, and detection, and prioritises actions. The control plan then documents the controls for high-risk items.

4. 12

   What are the key elements of a control plan?

   List part/process step, characteristic, specification, measurement method, sample size and frequency, control method, and reaction plan.

Behavioural and HR Questions

1. 13

   Tell me about a time you found a mistake in your own work. How did you handle it?

   Use STAR format. Show honesty, ownership, and what you learned. Avoid blaming others.

2. 14

   How would you handle a situation where a production supervisor pressures you to pass a nonconforming part?

   Emphasise quality and safety over pressure. Say you would politely refuse, escalate to your manager, and document the issue. Mention that customer trust is non-negotiable.

3. 15

   Why do you want to work as a Quality Engineer in a manufacturing company?

   Connect your interest in problem-solving, continuous improvement, and hands-on work. Mention that you enjoy seeing tangible results and learning about processes.

4. 16

   Are you comfortable working in shifts on the shop floor?

   Be honest. If yes, say so and show enthusiasm for learning from the floor. If no, explain any constraints but show flexibility where possible.