22563 Advanced Manufacturing Process External Oral / Viva Practice Questions with 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.