ENCO Engineers Combine hiring Spot-Welding Supervisor

Hiring | Spot Welding Supervisor 🚨

📍 Location: Dharuhera, Haryana
🏭 Industry: Automotive Sheet Metal Manufacturing

ENCO Engineers Combine Pvt. Ltd. is looking for an experienced Spot Welding Supervisor to join our production team.

Requirements:
✅ Minimum 4 years of experience in automotive sheet metal manufacturing
✅ Hands-on experience in Manual & Robotic Spot/Projection Welding
✅ Working knowledge of Fanuc, Kawasaki & Yaskawa robots
✅ Robot programming knowledge preferred
✅ Knowledge of IATF 16949, VSA, weld quality, production planning & process control
✅ Strong leadership, problem-solving and team management skills

Key Skills Required:

✔️ Experience in Manual & Robotic Spot / Projection Welding
✔️ Hands-on knowledge of Fanuc, Kawasaki & Yaskawa robots
✔️ Robot Programming knowledge preferred
✔️ Spot & Projection Weld Quality Standards
✔️ Automotive Sheet Metal Manufacturing experience (Mandatory)
✔️ Knowledge of IATF 16949, VSA & Quality Systems
✔️ Root Cause Analysis & Problem Solving
✔️ Advanced MS Excel & Google Sheets
✔️ Team Handling & Shop Floor Management
✔️ Strong Communication Skills

If you’re passionate about manufacturing excellence and have experience in automotive sheet metal welding, we’d love to hear from you.

📩 Share your resume at: talent@enco.in

📧 Email Subject Line: Application for Spot Welding Supervisor – Dharuhera

Spot Welding Supervisor Interview Questions and Answers (Automotive Sheet Metal Manufacturing)

If you’re applying for the Spot Welding Supervisor position at ENCO Engineers Combine Pvt. Ltd., these interview questions and answers will help you prepare for technical, production, quality, and leadership discussions.

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1. Tell us about your experience in Spot Welding.

Answer:

I have experience in automotive sheet metal manufacturing, handling both manual and robotic spot welding lines. My responsibilities include monitoring welding parameters, ensuring weld quality, reducing rejection, improving productivity, supervising operators, troubleshooting welding defects, and coordinating with maintenance and quality teams to achieve production targets.

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2. What is Spot Welding?

Answer:

Spot welding is a resistance welding process where two sheet metal parts are joined by applying pressure and electric current through copper electrodes. Heat generated due to electrical resistance melts the metal locally and forms a strong weld nugget.

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3. What factors affect weld quality?

Answer:

Major factors include:

• Welding Current
• Welding Time
• Electrode Force
• Electrode Tip Diameter
• Surface Cleanliness
• Material Thickness
• Electrode Alignment
• Cooling Water Flow

Improper control of these parameters leads to poor weld quality.

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4. What is Weld Nugget?

Answer:

The weld nugget is the fused metal formed between two sheets during spot welding. It is the actual joint responsible for weld strength.

Proper nugget size ensures good joint strength and durability.

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5. What are common Spot Welding defects?

Answer:

Common defects include:

• Weak Weld
• Expulsion
• Burn Marks
• Undersized Nugget
• Electrode Indentation
• Missing Weld
• Surface Crack
• Splash
• Porosity

Each defect requires root cause analysis before corrective action.

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6. What causes Expulsion during Spot Welding?

Answer:

Possible causes are:

• Excessive Welding Current
• Low Electrode Force
• Long Welding Time
• Dirty Material Surface
• Worn Electrode Tip

Corrective actions include optimizing welding parameters and dressing or replacing electrodes.

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7. What is Electrode Dressing?

Answer:

Electrode dressing restores the original shape and diameter of copper electrode tips.

Benefits:

• Improves current flow
• Maintains weld quality
• Increases electrode life
• Reduces rejection

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8. How do you ensure weld quality on the production line?

Answer:

I ensure:

• Parameter verification before production
• Daily weld testing
• Nugget testing
• Peel Test
• Chisel Test
• Visual Inspection
• Electrode maintenance
• Calibration of welding machines
• Process audits
• First-off approval

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9. Explain Peel Test and Chisel Test.

Answer:

Peel Test

Two welded sheets are separated manually to verify nugget formation.

Chisel Test

A chisel is inserted between welded sheets to check weld strength and nugget size.

Both tests verify weld quality.

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10. What is Projection Welding?

Answer:

Projection welding is similar to spot welding, but current is concentrated through raised projections on one component.

It is commonly used for:

• Nuts
• Bolts
• Brackets
• Reinforcements

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11. What is Robot Teaching?

Answer:

Robot teaching involves recording robot movement positions so it can repeat the same welding path accurately during production.

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12. Which welding robots have you worked with?

Answer:

I have experience with:

• Fanuc
• Kawasaki
• Yaskawa
• ABB (if applicable)

Responsibilities include:

• Program selection
• Backup
• Minor program modification
• TCP verification
• Production monitoring
• Basic troubleshooting

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13. What is TCP in Robot Welding?

Answer:

TCP (Tool Center Point) is the exact point where the welding gun performs the weld.

Incorrect TCP results in inaccurate weld positioning and poor quality.

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14. What is IATF 16949?

Answer:

IATF 16949 is the international Quality Management System standard for the automotive industry.

It focuses on:

• Customer satisfaction
• Defect prevention
• Continuous improvement
• Process control
• Risk management

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15. What is VSA?

Answer:

VSA (Vehicle Safety Audit) ensures welded vehicle components meet OEM safety and dimensional requirements before shipment.

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16. Explain the 7 QC Tools.

Answer:

The seven QC tools are:

• Check Sheet
• Pareto Chart
• Histogram
• Fishbone Diagram
• Scatter Diagram
• Control Chart
• Flow Chart

These tools help identify and solve quality issues.

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17. Explain the 5 Why Analysis.

Answer:

5 Why is a Root Cause Analysis technique.

Example:

Problem:
Weld failure

Why?
Low nugget size

Why?
Current low

Why?
Electrode worn

Why?
Dressing not done

Why?
PM schedule missed

Root Cause:
Preventive maintenance not followed.

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18. What is Poka-Yoke?

Answer:

Poka-Yoke means mistake-proofing.

Examples:

• Wrong part sensors
• Presence sensors
• Weld count verification
• Fixture interlocks
• Barcode validation

These prevent human errors.

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19. How do you reduce welding rejection?

Answer:

I focus on:

• Parameter optimization
• Electrode maintenance
• Robot calibration
• Operator training
• SPC monitoring
• Daily quality audits
• Root cause analysis
• Preventive maintenance

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20. How do you manage manpower on the shop floor?

Answer:

I allocate manpower based on production plans, monitor attendance, provide skill training, rotate operators, review performance, motivate the team, and ensure adherence to safety and quality standards.

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21. What production KPIs do you monitor?

Answer:

Important KPIs include:

• OEE
• Productivity
• Rejection Rate
• First Pass Yield (FPY)
• Machine Downtime
• Rework Percentage
• Line Efficiency
• Customer Complaints
• PPM
• On-Time Delivery

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22. What safety precautions should be followed in Spot Welding?

Answer:

Safety measures include:

• PPE usage
• Welding gloves
• Safety shoes
• Face shield
• Proper grounding
• Cooling water monitoring
• Lockout/Tagout (LOTO)
• Emergency stop checks
• Fire safety compliance

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23. How do you handle a sudden increase in welding rejection?

Answer:

I immediately stop the affected process, segregate suspect parts, inspect welding parameters, check electrodes and fixtures, perform root cause analysis using 5 Why or Fishbone, implement corrective actions, validate weld quality through testing, and restart production only after approval.

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24. Why should we hire you?

Answer:

I have strong experience in automotive sheet metal manufacturing with expertise in manual and robotic spot welding. I understand welding quality standards, IATF 16949 requirements, production planning, root cause analysis, and team management. I am committed to improving productivity, reducing rejection, ensuring customer satisfaction, and driving continuous improvement on the shop floor.

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25. What is your biggest strength as a Spot Welding Supervisor?

Answer:

My biggest strength is my ability to combine technical expertise with effective shop floor leadership. I can quickly identify production issues, coordinate with cross-functional teams, implement corrective actions, maintain welding quality, and motivate operators to achieve production, quality, and safety targets while fostering a culture of continuous improvement.