PRODUCTION INTERVIEW QUESTION &
ANSWERS
1) Explain the term BOM?
BOM stands for Bill Of Materials; it is a list of item or
parts that makeup a product assembly. For example, a
lawn mower requires a handle assembly, metal deck
assembly, a control assembly, motor and blade
assembly.
2) Explain what is DCR?
DCR stands for Document Change Request, a change
request which addresses about a problem with a
document, SOP (standard operating procedure) or
specification and propose a change to fix it.
3) Explain what is Kanban?
Kanban is scheduling system which advises
manufacturers about how much to produce, what to
produce and when to produce. In this system,
inventory is re-filled only when visual cues like an
empty bin or cart is seen.
4) Explain what is MES?
MES stands for a system that manages and controls
the production on the factory floor with the motive of
reducing the total time required to produce an order.
5) Explain what is Six Sigma?
Six sigma is a data-driven methodology and approach
for eliminating defects in any process from
manufacturing to transactional and from product to
service.
6) What is the difference between lean
manufacturing and JIT (Just-in-Time) Manufacturing?
Lean Manufacturing: It takes the concept of JIT
and re-examines it from the customer point of view.
Anything that is produced should add something of
valuable to the customer’s requirement. For
example, if you are making stereo system for a
luxury car, you will think from the customer point of
view like sound quality, durability, space occupancy,
loud or medium sound, etc.
JIT (Just-in-Time): This methodology is designed
to ensure that a product or part would arrive just in
time to be used. This technique saves the cost
behind the unused inventory, and eliminating the
need of piling up inventory.
7) Explain what is QMS?
QMS stands for Quality Management System; it
documents all necessary information about company’s
design and operational controls, including issue
reporting, monitoring, continuous improvement and
training, to make sure that company delivers
continuous product.
8) Explain what is batch production?
Batch production is a manufacturing technique, where
components or goods are produced in groups and not
in a continuous stream. This methodology is mainly
used when similar items are produced together.
9) What is the challenge in manufacturing
products?
Main challenge in manufacturing is to develop better
production processes, ensure the right material and
component supplies at the least cost, decrease
production time, eliminate wastage and maintain
quality in the final product.
10) List out the factors that can affect the
manufacturing process?
The factors affect the manufacturing process are
Supplies: A well-managed supply and inventory is
very crucial in order to run manufacturing process
smoothly. The manufacturers must brace themselves
up and ready to overcome any unexpected delays in
supplies due to weather or transportation hindrance.
Equipment: Equipment’s are the central unit for
any manufacturing plant; regular maintenance are
utmost necessary to avoid a breakdown in the middle
of production. Identify the means of improving the
efficiency of every part of the equipment.
Factory Overhead: Without power supply,
manufacturing is not possible. Always keep plan B
ready in case of temporary power cut down.
Special Parts: Replacing any special spare parts
with different specification may slow down your
production, so before ordering any special spare
parts ensure it fits your demand especially if it is
imported from long distance.
Work Force: Human resource is equally important
and plays a major role in manufacturing unit.
11) Define the term “factory overhead”?
During the manufacturing process, whatever the cost
is incurred during the process is referred as “factory
overhead”, excluding the cost of materials and direct
labours.
12) List out some of the examples of factory
overhead?
Following are the overheads
a production manufacturing engineer has to consider:
Factory rent
Utilities used in the unit
Costs behind equipment set up
Costs behind equipment maintenance
Production unit supplies
Insurance covered on equipment’s and production
facilities
Fringe benefits
Depreciation
QA Salaries
Property taxes on manufacturing facilities
Material management salaries
13) Explain how to supervise in a manufacturing
unit?
Supervising a manufacturing process includes
attending to the individual phases of the production.
Also, manufacturing supervisor should have a close eye
on the inventory that going to be used.
Step 1: Keep the records of different phases of
manufacturing also analyse whether the amount of
product produced by the crew is enough to meet the
demand.
Step 2: Look for the bottlenecks in the unit and
see how you can eliminate it.
Step 3: Keep the track of inventory and try to
reduce the liquid capital used after unused material.
Step 4: Examine the final goods to determine
whether they meet the company’s quality standards.
14) Explain how can you calculate manufacturing
work in progress?
Manufacturing work in progress is when
manufacturing firm transforms material into the work
in process which includes raw material, labour and
factory overhead. You can calculate all the below
factors to know the costing for the manufacturing work
in progress.
labour costs
Raw material inventory costs
Production cost
Cost of ending work in process for the accounting
period
15) Explain what is product report?
A product report is a general term used to represent
design, manufacturing, quality, sales and repair
information about a product.
16) Explain what is RMA?
RMA stands for Return Material Authorization; it is a
financial and work order tracking used to determine a
returned item’s origination. It is often used in a
transaction where a customer returns goods to the
manufacturer for replacement or repair purpose.
17) Explain what is SCAR (Supplier Corrective Action
Request)?
Manufacturers are highly dependent on their raw
material suppliers, to communicate with them
effectively SCAR is used. It is a change request that
mentions the issues with the process or material from
a supplier and ask for a resolution. It sometimes also
includes the details about how the complaint should be
addressed.
18) What are the softwares which can be useful in
manufacturing unit?
In manufacturing unit, software that can be useful
are Manufacturing ERP and Material
Management. Some of the companies that provide the
manufacturing software solution are SAP, Oracle ERP
system, etc.
19) Explain what is GMP?
GMP is a good manufacturing practice and is
recognized worldwide for the control and management
of manufacturing and quality control testing of foods,
medical devices and pharmaceutical products.
20) Explain what are the approach used in
manufacturing for QA?
For QA in manufacturing techniques used are
Acceptance sampling: In this testing, a random
sample is picked from the batch rather than testing
the whole batch.
Statistical process control: Through the use of
control charts and data collected for the samples at
the various stages of production a manufacturing
product can be monitored.
Troubleshooting studies: At the end of the line
product, a trouble-shooting study can be carried out
to see whether the changes in the inputs are
associated with the output variables
