Chapter 18: QA/QC Interview Preparation & Field Challenges
This final chapter prepares you for real-world interviews and on-site situations faced by QA/QC engineers in mechanical industries (oil & gas, power plants, fabrication yards, refineries, HVAC projects, etc.).
🎯 1. Common QA/QC Interview Questions
| Question | Purpose |
|---|---|
| Explain the difference between QA and QC | Checks concept clarity |
| What is WPS, PQR, and WPQ? | Welding knowledge |
| How do you handle an NCR? | Problem-solving skill |
| What are the steps in hydrostatic testing? | Field knowledge |
| How do you prepare a final QA/QC dossier? | Project experience |
🛠️ 2. Practical Field Challenges (with Solutions)
| Challenge | Solution |
|---|---|
| Client rejected material due to missing MTC | Always verify MTCs and vendor compliance at receipt |
| Welder used wrong electrode | Cross-check WPS, give toolbox talk, and issue NCR |
| Inspection agency delayed reports | Maintain parallel documentation; push through follow-up |
| Paint thickness not as per spec | Re-inspect and re-coat; document with DFT (Dry Film Thickness) gauge |
| Site crew skips hold point inspection | Train team on ITP flow; log incident in QA logbook |
📋 3. Soft Skills for QA/QC Engineers
Assertive communication with contractors & client reps
Document handling and traceabilityReporting and email writing
Leadership in audits and inspections
Conflict resolution when handling NCRs
🔍 4. Key Focus Areas Before Attending Interview
| Topic | Why Important |
|---|---|
| ISO 9001 clauses | Core standard in QA systems |
| NDT methods (RT, UT, PT, MPI) | Inspection skillset |
| Welding documentation | Crucial for fabrication QA/QC |
| Calibration practices | Used in all measurement tasks |
| Pressure testing | Project critical activity |
| Material traceability | Client compliance must |
🧪 5. Mini Project Assignment (For Revision & Practice)
Scenario: You are a QA/QC engineer on a gas pipeline project. Prepare the following:
List of inspection checklists needed
Sample ITP for welding & NDTA punch list format
One sample NCR & corrective action
Final QA Dossier index page
🧠 6. Bonus Tips for Freshers
Create a file of 10+ sample QA/QC forms (MIR, WIR, RFI, NCR, etc.)
Learn to read technical drawings and P&IDsDo mock interviews with experienced QA/QC professionals
Build familiarity with ISO, ASME, and API standards
Chapter 18: MCQs – Interview & Field Challenges
Q1. What does the abbreviation NCR stand for in QA/QC?
A) National Control Requirement
B) Non-Conformance Report
C) New Contractor Request
D) Normal Calibration Record
🟩 Correct Answer: B
Q2. Which of the following is not part of a final QA/QC dossier?
A) Hydrostatic Test Report
B) Welding Procedure Specification
C) NCR Log
D) Manpower Salary Sheet
🟩 Correct Answer: D
Q3. You are at site and a weld is completed without any inspection request. What should you do first?
A) Ignore the issue
B) Issue RFI post-weld
C) Raise an NCR and investigate
D) Ask the welder to weld again
🟩 Correct Answer: C
Q4. Which test is used to verify paint thickness on coated surfaces?
A) Ultrasonic Thickness Test
B) DFT Test (Dry Film Thickness)
C) Dye Penetrant Test
D) Pressure Test
🟩 Correct Answer: B
Q5. If an equipment’s calibration certificate is expired, what should the QA/QC engineer do?
A) Use the equipment anyway
B) Manually approve readings
C) Remove from service and recalibrate
D) Ignore it for non-critical items
🟩 Correct Answer: C
Q6. What is the first action to take when a non-conformance is observed?
A) Fire the responsible person
B) Document it in an NCR
C) Inform the client only
D) Continue work
🟩 Correct Answer: B
Q7. Which of the following is a good QA/QC practice during project handover?
A) Delete old records
B) Submit final documents without index
C) Archive all QA records and provide an indexed dossier
D) Skip rejected item logs
🟩 Correct Answer: C
Q8. A client asks for ITP, but you don’t have it on site. What does this indicate?
A) Perfect documentation
B) Incomplete QA preparation
C) Well-organized QA plan
D) Updated drawings
🟩 Correct Answer: B
Q9. Who is responsible for issuing the RFI (Request for Inspection)?
A) Safety officer
B) Planning engineer
C) QA/QC engineer or inspector
D) Accountant
🟩 Correct Answer: C
Q10. What is the main purpose of a punch list during handover?
A) To evaluate salary
B) To track pending tasks and rectifications
C) To reject materials
D) To issue new tenders
🟩 Correct Answer: B