What do you do if your problem-solving abilities are tested in a manufacturing operations interview?

During manufacturing operations interviews, I demonstrate my problem-solving skills by applying lean principles. This includes utilizing value stream mapping to analyze production processes visually, pinpointing inefficiencies, and improving material and information flow.

Throughout this process, effective communication among team members and stakeholders is crucial. It's also important to involve those who are directly affected by the problem and the solution to ensure buy-in and successful implementation.

Always good to have What if? scenarios planned out ahead of any interview. Ask a friend or colleague to quiz you in a dialogue. Keep your answers to the point and direct. Relying on experiences is always better than hypotheticals.

In my experience, I ask targeted questions to understand all the conditions the problem creates, and then break it down into smaller sections to fully understand the why's of each condition. Next step is root cause analysis using the A3 Thinking systematic PDCA approach.

Para poder solucionar un problema primero debes conocer la situación actual, colectar la mayor información posible, así como los indicadores del proceso que puedan estar fuera del objetivo, también investiga cuales son los objetivos de la compañía y si estos están alineados a los objetivos del proceso.

Para analizar un problema debes crear un equipo multidisciplinario que este involucrado en el proceso a resolver, posterior a esto debes buscar la causa raíz para lo cual puedes utilizar un 5 porqués, lluvia de ideas o ishikawa.

While in an interview, if I'm questioned about the problem solving abilities then I will explain it either with my actual experience or create a hypothetical problem. The basics of the problem solving starts with the understanding of the problem first, using 5-Why analysis. Drill down to identify the problem or sometimes need to focus on potential problems. For me, identifying the root cause of any problem, makes the problem half solved. For best solutions, I'll sit with the cross-functional team and brain storm to list down the possible solutions and select the one which should be cost efficient, effective and achievable.

The use of lean tools have never failed me. The key is do not accept preconceived answers. Let the data (not select data) lead you to the root cause.

Root cause analysis using why-why technique is a proven tool to get deep into the problem analysis, uncover underlying issues and implement solutions systematically.

In case I am ask to describe how I would solve a hypothetical problem, it is good to know that very often it is not about giving (the only one) right answer/solution, but rather about demonstrating your approach when solving an issue. So do not freak out if you do not know all the steps up until the very last one which lead to a successful solution. Sometimes it is not only a test of your hard skills but soft skills, too, which means you should also demonstrate your ability to admit you need consultation/advice from other colleagues or simply more information.

emphasize the use of a methodical process to test various resolutions, such as the PDCA (Plan-Do-Check-Act) cycle. Describe how you would plan a course of action, carry it out on a limited scale, evaluate the results to ensure efficacy, and then take appropriate action to either permanently adopt the change or restart the cycle if needed.

I would emphasize the importance of offering solutions in a structured manner. By highlighting the PDCA (Plan-Do-Check-Act) cycle, I would stress the systematic approach of planning, implementing on a small scale, checking results, and taking action to make changes permanent. This methodical process demonstrates a results-driven mindset crucial for success in manufacturing operations.

Al conocer la causa raíz del problema debes buscar acciones de contención para mitigar el problema y acciones permanentes correctivas para evitar que vuelva a ocurrir el problema de fondo.

Organization should be careful to reward correctly those involved in the problem solving process after the solutions. This will ensure a continuous flow of mitigating problems and bullet proof the potential of issues recurrence.

I agree that it is definitely wise to provide your solution in such a way which is structured and "tecnical" - not a mere loose description of what steps you "probably" might take to arrive at your suggested solution. Now, for every step within the - for instance - Plan-Do-Check-Act approach it is good to come with an example of a similar problem you have already encountered and successfully solved. This again gives your answer a more credibility as it is obvious then you know what you are talking about and not that you area just dully delivering lines from textbooks you learned almost by heart. Even mentioning your mistake in history is good - an evidence you are able to admint and learn from your mistakes.

Cuando estes platicando con el equipo de trabajo fomenta el usar las palabras que utilizan en el proceso y evita utilizar palabra complejas que el equipo no pudiera entender.

Clear communication across and up and down the organization when problem solving is critical to be able to make business decisions with accurate information. I’d recommend getting feedback from management and making sure you have a way to highlight if resources are needed to solve the problem faster.

Although it depends on the round of the job interview as well as on the size of the comany you are applying at, most of the time you will be talking to a person/people who are not so much into all the theoretical methodologies and terms, but who are very practical and rather want to hear from you exactly how you are going to help them solve problems and to fulfill your tasks. Nothing more, nothing less. Though it is good to "spice" a little bit your answers with professional terminology, again, do not overdo it (above all not to that extend so that you do not understand yourfelf any more :-) ).

The answer is always team! As an operations manager, if you’re coming in with the ambition to solve all of the problems based on your personal experience and skill set, you will always be just that, a manager. Scrambling from fire to fire. Instead, step up as an Operations Leader! Explain how you’ll unite the team and orchestrate solutions, utilized the tools already in place to create a systematic process to address issues while involving the entire team. Creating accountability and ownership will not only get more people involved, but they’ll feel more productive and appreciated which supports longevity. Don’t be that know it all, do it all manager. Bring true leadership to the interview and your chances of getting hired skyrocket!

The experience of each team members will play a lot in this aspect. Many years of collaborating with fellow workers will help a lot in attacking the issues at hand.

Para solucionar el problema recuerda que debes crear un equipo multidisciplinario, crea un buen ambiente de trabajo para que todos participen en la búsqueda de la causa raíz y la solución del problema.

When looking for rootcauses and associated solutions I find it very helpful to engage with both team members as well as otger contributors/stakeholders in the organisation. This will provide solutions which inevitably carry eide acceptation.

Show your modesty and that you are able to appreciate other peoples ideas, contribution, opinion, respect their different abilities etc. In your new position, definitely you are not supposed to solve all the issues on your own without having chance to shart the burden, delegate some task and, on the contrary, help out with things that officially you are not responsible for... if you manage to mention your awarenes of this, it will be another extra points for you.

Yes, of course, who would describe themselve during a job interview as a stubborn inadaptable guy? :-) Yet again, I believe one should be honest, above all. So do not lie and do not try to make you appear as a Nobel Peace Prize as well as Nobel Manufacturing Prize. Alghough an adaptable, open-minded, friendly... person will always be 100-times more preffered to a person with opposite traits, it is good to mention some pety bad feature of yours you are aware of and you are trying to cope with/suppress. It again gives your answers much more credibility. Finally, I would always much rather work with an honest then a brilliant flawless guy, if by any chance no honest AND brilliant flawles guy showned up for the interview.

Adaptability is a key trait that makes a difference between an average engineer and an exceptional engineer. Your adaptability to solve a new problem resulting from your initial solution is crucial to an employer. This is where your thinking out-of-the-box solutions need to be presented, an example case where you didn't accept an answer such as "but this is how we have always done it". For example, had a case where we needed to zero out over 1000 late parts in processing. The solution was to stop advancing the parts as formal kits family and assemble the kits back together only at the shipping station, thus enabling eliminating kits late delivery due to parts holds.

If anyone engineer has the basic knowledge of the fundamentals of mechanical engineering, problem solving should not be an issue to worry about. The theory and experimentation done in a Mechanical Engineering Course should by default develop problem solving abilities in the candidate appearing for the interview if the degree was taken even a bit seriously depending on the rigorous syllabus we have.

Examples of problem solving situations can be used to demonstrate process, competency, skills in problem solving and one’s mental state and ability remain calm and have a structured, analytical approach.

1. Anticipate the types of question 2. Prepare relevant examples 3. Know what the problem is worth in marginal contribution or reduced cost. Do the numbers properly, someone will pick holes in them 4. Show that you can use a structured process (DMAIC, fault tree) to find deep insight into why the process was failing. Be concise but accurate in conveying correct understanding of how things work. This should be accurate but understandable to a layman 5. Show how you proved the theory was correct and what you did to engineer a permanent solution 6. Show how you overcame obstacles. Be prepared to talk about goal orientation, leading others and dealing with roadblocks 7. Be prepared for counter questions. Listen, think before you speak