Kirloskar Production Engineer Interview: Rounds, Questions and Preparation

What the job involves

Production Engineers in manufacturing and automobile companies plan and supervise daily production activities on the shop floor, ensuring that output meets targets, quality standards, and safety norms. They coordinate with maintenance, quality, and supply chain teams to reduce downtime, improve cycle times, and implement lean manufacturing practices. The role involves hands-on problem solving, data tracking, and continuous improvement of processes such as machining, assembly, and fabrication.

Role and Technical Knowledge

1. 1

   What is the difference between production and productivity? How would you improve productivity on an assembly line?

   Define production as output volume and productivity as output per unit input (labor, machine, material). Suggest improvements like reducing cycle time, eliminating waste, or balancing line stations.

2. 2

   Explain the concept of takt time and how it helps in production planning.

   Takt time is available production time divided by customer demand. It sets the pace for the line and helps in allocating work evenly and identifying bottlenecks.

3. 3

   What are the seven wastes in lean manufacturing? Give an example from an automobile plant.

   List the seven wastes: overproduction, waiting, transport, overprocessing, inventory, motion, defects. Give a specific example like excess inventory of engine parts between stations.

4. 4

   How would you calculate Overall Equipment Effectiveness (OEE)? What does a low OEE indicate?

   OEE = Availability x Performance x Quality. A low OEE points to downtime, speed losses, or quality defects. Mention how to track each component and take corrective action.

Practical Scenarios

1. 5

   A critical machine on your line breaks down repeatedly, causing delays. How do you handle it?

   Describe immediate steps: inform maintenance, log downtime, use root cause analysis (5 Why or Fishbone) to find the underlying issue, and implement preventive maintenance. Mention coordination with the maintenance team and tracking MTBF/MTTR.

2. 6

   You notice that a batch of components has a dimensional deviation. What do you do?

   Stop production if needed, segregate the batch, inform quality, use control charts to check if the process is in control, and investigate causes like tool wear or machine setting. Suggest corrective and preventive actions.

3. 7

   How would you reduce setup time on a CNC machine?

   Apply SMED (Single Minute Exchange of Die) principles: separate internal and external activities, convert internal to external, streamline tasks, and use standard work. Mention quick-change tooling and pre-staging materials.

4. 8

   Your team is resistant to a new 5S initiative. How do you get them on board?

   Explain the benefits (safety, efficiency, easier work), involve team members in planning, start with a pilot area, provide training, and recognize early adopters. Show quick wins to build trust.

Behavioural and Situational

1. 9

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

   Use STAR format: describe the situation, your task, the actions you took (communication, delegation, prioritization), and the result. Highlight collaboration and keeping calm.

2. 10

   How do you handle a situation where a senior operator disagrees with your process change?

   Show respect for experience, listen to concerns, explain data and rationale behind the change, and seek a trial run. Emphasize data-driven decisions and maintaining harmony.

3. 11

   Describe a time you made a mistake. What did you learn?

   Choose a real but not catastrophic mistake. Explain what went wrong, how you fixed it, and the preventive measure you now follow. Show accountability and learning.

4. 12

   Are you comfortable working in shifts and on the shop floor? Why?

   Answer honestly and positively. Mention willingness to learn from the floor, adaptability, and understanding that production roles often require shift work. Relate to long-term career growth.

HR and Company Fit

1. 13

   Why do you want to join the manufacturing sector, and what interests you about our company?

   Connect personal interest in making things, problem-solving, and continuous improvement. Research the company's products, reputation, and values. Avoid generic answers.

2. 14

   Where do you see yourself in five years in a production role?

   Show ambition to grow into senior production engineer or manager, with emphasis on mastering processes, leading teams, and contributing to operational excellence. Align with company growth.

3. 15

   How do you prioritize safety versus production targets?

   State clearly that safety comes first. Explain that unsafe practices lead to long-term losses. Give an example of following safety protocols even under pressure.

4. 16

   What are your salary expectations for this role?

   Research industry standards for freshers in manufacturing. Give a range based on location and company size, and express flexibility and focus on learning and growth.