Sundram Fasteners Quality Engineer Interview: Rounds, Questions and Preparation

What the job involves

Quality Engineers in manufacturing ensure that products and processes meet defined quality standards and customer requirements. They use tools like inspection, testing, statistical process control, and root cause analysis to prevent defects and drive continuous improvement. In automobile and engineering firms, they work closely with production, design, and suppliers to maintain quality from raw material to finished part.

Role and Technical Knowledge

1. 1

   What are the 7 QC tools and how have you used any of them in a project or lab?

   Name the tools (check sheet, histogram, Pareto, cause-and-effect, scatter, control chart, flowchart) and give a brief example of using one to solve a problem.

2. 2

   Explain the difference between accuracy and precision in measurement.

   Define accuracy as closeness to true value and precision as repeatability; relate to measurement system analysis.

3. 3

   What is the purpose of a control plan in an automotive manufacturing process?

   Describe how it specifies inspections, frequency, methods, and reaction plans to keep processes in control.

4. 4

   How does GD&T help in ensuring part quality and interchangeability?

   Explain how geometric tolerances communicate design intent and allow functional assembly without unnecessary tight tolerances.

Practical Scenarios

1. 5

   A customer reports a high rejection rate for a fastener due to thread damage. How would you investigate?

   Outline a structured approach: contain, gather data, use fishbone or 5 Why, check process parameters, and implement corrective actions.

2. 6

   During an audit, you find that a supplier's material certificate does not match the received lot. What steps do you take?

   Mention segregation, documentation, communication with supplier, and initiating a supplier corrective action request.

3. 7

   You notice that a machine's process capability (Cpk) is below 1.33. What actions would you consider?

   Discuss reducing variation, adjusting process centering, improving measurement system, and possibly redesigning tolerances.

4. 8

   How would you handle a situation where production wants to ship parts that are slightly out of specification to meet a deadline?

   Emphasize adherence to quality standards, escalation to management, and using a deviation or concession process if appropriate.

Behavioural and Situational

1. 9

   Describe a time when you had to convince a team to follow a quality procedure they found inconvenient.

   Use STAR format: explain the situation, your approach to communication, and the positive outcome.

2. 10

   Tell me about a mistake you made in a project or internship and what you learned.

   Show honesty and reflection, focusing on the lesson and how you improved your process.

3. 11

   How do you prioritize when you have multiple quality issues to address at once?

   Discuss risk-based prioritization, impact on customer, and using data to decide urgency.

4. 12

   Give an example of how you worked in a team to achieve a common goal.

   Highlight collaboration, your specific role, and how you handled differing opinions.

HR and Company Fit

1. 13

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

   Connect personal interest in problem-solving and continuous improvement to the sector's importance in safety and reliability.

2. 14

   What do you know about our company and its quality standards?

   Research the company's products, markets, and any known certifications; mention how quality is critical to their reputation.

3. 15

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

   Show ambition to grow into areas like quality management, auditing, or supplier quality, while staying grounded in learning.

4. 16

   Are you willing to work in shifts and on the shop floor if required?

   Be honest and positive; express flexibility and eagerness to learn from hands-on experience.