Tell us about a production problem you encountered and how you resolved it.

Sample answer to the question

In my previous role as a Junior Industrial Engineer, I encountered a production problem where we were experiencing a high defect rate in the final product. After investigating the issue, I discovered that the problem was due to a faulty machine calibration process. To resolve the issue, I created a detailed standard operating procedure (SOP) for machine calibration and trained the operators on the new process. Additionally, I implemented a thorough quality control system to catch any defects early in the production process. These measures resulted in a significant reduction in the defect rate and improved overall product quality.

A more solid answer

In my previous role as a Junior Industrial Engineer, I encountered a production problem where we were experiencing a high defect rate in the final product. To address the issue, I followed a systematic problem-solving approach. First, I conducted a thorough analysis of the production process, examining each step to identify potential causes of the defects. After careful examination, I found that the problem was due to a faulty machine calibration process. To resolve the issue, I created a detailed standard operating procedure (SOP) for machine calibration, ensuring that all calibration parameters were clearly defined. I then trained the operators on the new process, emphasizing the importance of following the SOP accurately. Additionally, to prevent defects from going unnoticed, I implemented a comprehensive quality control system. This system involved regular inspections at each stage of the production process, allowing us to identify and address any issues early on. As a result of these measures, we saw a significant reduction in the defect rate, improving overall product quality.

Why this is a more solid answer:

The solid answer provides more specific details about the problem-solving process, including the systematic approach taken to analyze and identify the root cause of the production problem. It also highlights how the candidate applied their analytical thinking and attention to detail to create a detailed standard operating procedure. However, the answer could still be improved by discussing how the candidate managed their time and worked on multiple projects simultaneously while resolving the problem.

An exceptional answer

In my previous role as a Junior Industrial Engineer, I encountered a production problem related to a high defect rate in the final product. Recognizing the importance of promptly addressing this issue, I took a proactive approach to resolving it. I began by conducting a thorough analysis of the entire production process, scrutinizing each step and collecting data to identify potential causes of the defects. This analysis revealed that the problem stemmed from a faulty machine calibration process, resulting in inconsistent product quality. To rectify this, I collaborated with the maintenance team to calibrate and fine-tune the machines, ensuring their accuracy and reliability. Simultaneously, I developed a comprehensive quality control system that involved implementing regular inspections at every stage of production. These inspections allowed us to catch any defects early, preventing them from reaching the final product. To streamline the process, I also created an interactive online dashboard that provided real-time data on defect rates and highlighted any areas of concern. By constantly monitoring the dashboard, we were able to quickly address any emerging issues. As a result of these efforts, we saw a drastic reduction in the defect rate, significantly improving product quality. This achievement not only earned recognition from management but also instilled a sense of pride and motivation within the team.

Why this is an exceptional answer:

The exceptional answer goes above and beyond by providing even more specific details about the problem-solving process. It highlights the candidate's proactive approach and their collaboration with other teams to resolve the issue. The answer also demonstrates the candidate's capacity to work on multiple projects simultaneously by mentioning their simultaneous work on machine calibration and implementing a quality control system. Additionally, it showcases the candidate's technical skills by mentioning the creation of an online dashboard for monitoring and analyzing data. Overall, the exceptional answer demonstrates a comprehensive understanding of the production problem and showcases the candidate's ability to go the extra mile to find innovative solutions.

How to prepare for this question

Familiarize yourself with the various steps involved in problem-solving, such as problem identification, root cause analysis, and solution implementation.
Highlight your experience in analyzing complex systems and processes to demonstrate your ability to identify potential causes of production problems.
Emphasize your attention to detail and analytical thinking skills to showcase your ability to investigate issues thoroughly.
Discuss any experience you have with process improvement techniques, such as Six Sigma or Lean Manufacturing, as these skills are highly valued in this role.
Provide examples of your ability to work on multiple projects simultaneously while adhering to schedules, as this demonstrates your capacity to handle the demands of the position.

What interviewers are evaluating

Analytical thinking and attention to detail
Problem-solving abilities
Technical writing ability
Understanding of process improvement techniques
Capacity to work on multiple projects simultaneously while adhering to schedules