Can you provide an example of a manufacturing process issue you solved using your knowledge of automation and information technology?

Sample answer to the question

Yeah, I handled this one time when a conveyor belt malfunction was causing major delays in our packaging line. I drew upon my programming skills and knowledge of automation to create a quick solution. I wrote a small program that analyzed the timings and operations of the belt, identifying the inconsistency in speed that was causing packages to jam. After that, I adjusted the control system to stabilize the belt speed using Python, and that solved the problem. This increased the efficiency and got the line back up to speed in no time.

A more solid answer

Absolutely, there was a time at my last job where we faced an issue with an automated welding machine that was causing defects in our car manufacturing process. After a thorough analysis, I discovered that the issue was due to a synchronization error between the welding robot and the conveyor system. Applying my programming skills, I created a new algorithm in C++ that improved the communication protocol between the PLC and the robot. This resulted in a smoother handover of parts from conveyor to welding robot, which not only resolved the defects but also improved the overall throughput by 15%. My team and I worked closely to test and integrate this fix, ensuring it fit perfectly within the existing system.

Why this is a more solid answer:

The solid answer builds on the basic one by offering a specific automation problem related to a car manufacturing process, demonstrating the analytical skills and programming proficiency expected from the job description. It also highlights successful teamwork and the integration of a solution into an existing system. However, the answer could further expand on how the candidate utilized CAD software for system design and how they communicated the problem and its solution to non-technical staff.

An exceptional answer

Certainly! In my prior role at an automotive factory, we encountered a complex issue where the assembly robots were intermittently misaligning components, leading to significant production delays. Diving deep into analytics, I traced the problem to outdated firmware causing communication delays in the industrial network. Leveraging my coding expertise, particularly in Python, I developed a diagnostic tool to monitor the network traffic and pinpoint bottlenecks. Following this, I updated the firmware and optimized the message queuing system to improve synchronization. This fix was articulated through a CAD-designed enhancement to the system, which I presented to both my engineering team and the non-technical stakeholders, ensuring everyone understood the improvements. My efforts not only rectified the issue but also increased production efficiency by 20% and reduced material wastage. Additionally, the solution set the stage for a future-proofing project that I spearheaded, integrating the newest automation standards into our processes.

Why this is an exceptional answer:

The exceptional answer gives a comprehensive problem-solving narrative centered around an assembly robot issue that directly ties into the responsibilities and skills listed in the job description. The candidate showcases their strong analytical skills, programming expertise (specifically in Python), industrial network knowledge, and proactive communication with both engineers and non-engineers. The resolution involved sophisticated diagnostics, a firmware update, system optimization, a CAD-designed system enhancement, and the launch of a future-proofing initiative, all demonstrating a broad and deep capability set. Such detail demonstrates leadership and the ability to manage a project from problem identification through to a successful and sustainable resolution.

How to prepare for this question

Prepare examples of specific projects where you successfully applied analytical and problem-solving skills to automation. Include metrics, if possible, to demonstrate the impact of your solution.
Be ready to discuss programming challenges you've faced, particularly with languages listed in the job description (C++, Python, Java). Reflect on your thought process and the steps you took to overcome these issues.
Highlight any experience with CAD software by discussing how you've used it in designing automated systems and how it contributed to solving a problem.
Mention instances of teamwork and effective communication, emphasizing how you've worked with both technical and non-technical stakeholders.
Discuss your familiarity with industrial networks and communication protocols, providing examples of how you've integrated solutions into industrial systems, and how that led to improvements.

What interviewers are evaluating

Analytical and problem-solving skills
Programming skills
Knowledge of industrial networks and communication protocols
Experience with integrating automation solutions
Teamwork and communication