Auto-Sector Interview Preparation

Develops product designs and specifications that meet functional, cost and manufacturing requirements.

Computer-Aided Design, software used to create 2D and 3D models.

CATIA, Siemens NX, SolidWorks, Creo and AutoCAD.

2D shows flat views and drawings; 3D represents the object in space with volume.

Geometric Dimensioning and Tolerancing, a system to define part geometry and allowable variation.

The allowable variation in a dimension.

A reference feature from which other dimensions are measured.

A part is a single component; an assembly is several parts joined together.

A structured list of all parts and materials in a product.

Design for Manufacturing, designing parts so they are easy and cheap to make.

Design for Assembly, designing so parts are easy to assemble.

A rounded internal corner that reduces stress concentration.

An angled edge, often used to ease assembly or remove sharp edges.

A slight taper on a moulded or cast part that allows easy removal from the mould.

Finite Element Analysis, a numerical method to simulate stress, deflection and other behaviour.

A localised increase in stress, usually at a sharp corner or hole.

The stress at which a material begins to deform permanently.

The maximum stress a material can withstand before breaking.

Ductile materials deform before breaking; brittle materials break with little deformation.

Lightweight components such as body panels, engine blocks and wheels.

A high strength-to-weight ratio for lighter, stiffer parts.

A component such as a bolt, screw or rivet used to join parts.

A bolt is used with a nut; a screw threads directly into a part.

The accumulation of individual tolerances across an assembly.

A technical drawing that communicates dimensions, tolerances and notes for manufacture.

A view that shows internal features by cutting through the part.

A view that shows assembly components separated to reveal how they fit.

Designing for the comfort, safety and ease of use of the occupants.

Body In White, the welded vehicle body structure before paint and trim.

Shaping flat metal sheets into parts by bending, stamping or drawing.

A process that makes plastic parts by injecting molten plastic into a mould.

To seal the joint between two surfaces and prevent leaks.

An interference fit where parts are held together by friction.

The ratio of a material strength to the actual applied load.

Recreating a design by measuring and analysing an existing product.

An early sample built to test and validate a design.

A recorded change to a drawing, tracked with a revision number.

Computer-Aided Manufacturing, software that drives machine tools from CAD data.

Strength resists failure; stiffness resists deformation.

A geometric property describing resistance to bending or rotation.

The condition where a feature contains the most material, used to allow bonus tolerance.

Position controls the location of a feature; concentricity controls the axis relationship.

Sum the contributing tolerances using worst-case or statistical methods to verify the assembly fit.

Worst-case adds all extremes; statistical uses root-sum-square for a realistic result.

Consider strength, weight, cost, manufacturability, corrosion resistance and the load case.

Static, dynamic, fatigue and impact loads.

Failure under repeated loading below yield; design with smooth transitions, low stress and good materials.

A graph relating cyclic stress to the number of cycles to failure.

Use topology optimisation, ribbing, lighter materials and removal of non-load-bearing material.

A method that removes material from low-stress regions to minimise weight while meeting load requirements.

It predicts stress, deflection, modes and fatigue so issues are found before prototyping.

The division of a model into elements; a finer mesh gives more accurate but slower results.

Loads, constraints or supports and material properties that represent real conditions.

To find a structure natural frequencies and avoid resonance.

Noise, Vibration and Harshness, the study and control of unwanted sound and vibration.

Use standard bend radii, avoid tight tolerances, minimise operations and allow for tooling.

Reduce part count and use self-locating features, standard fasteners and symmetric parts.

It defines functional relationships clearly and often allows more usable tolerance.

Thermoplastics can be remelted; thermosets cure permanently.

Based on the joint load, materials, thread size and the required clamp force.

A model driven by dimensions and relationships so that changes update automatically.

To identify and mitigate potential design failure modes early.

Identify the high-stress region and add material, fillets or ribs, or change the material or geometry.

Casting pours molten metal into a mould; forging shapes metal under pressure for better grain strength.

Tighter tolerances increase machining cost, so choose the loosest tolerance that works.

Through material choice, coatings, galvanic isolation and avoidance of water traps.

Static assumes steady loads; dynamic accounts for time-varying loads and inertia.

Uniform wall thickness, draft angles, avoidance of thick sections and proper rib design.

The ability of the structure to protect occupants by absorbing crash energy.

They deform progressively to absorb impact energy and reduce the force on occupants.

Clearance leaves a gap; interference creates an overlap requiring force to assemble.

It reduces cost, simplifies sourcing and improves reliability through proven parts.

Through analysis, prototyping, design verification and validation testing, and design reviews.

A structured evaluation of a design by stakeholders to catch issues early.

Optimise the trade-offs against requirements using analysis and value engineering.

Use topology optimisation and smooth load paths with fillets to cut stress, then verify with fatigue FEA against S-N data.

Check the cyclic loads, stress concentrations, surface finish, residual stress and material defects, then redesign and re-test.

Define the datums and loop, list contributors, apply worst-case or statistical methods, then verify against the gap with margin.

Shift the natural frequency by changing stiffness or mass, add damping, or isolate the source.

Trade weight savings against cost, formability, joining method, repair and stiffness targets.

Maintain uniform wall thickness, add draft and fillets, avoid hot spots, and verify with casting and structural simulation.

Ensure adequate preload, the correct grade and a locking method, and keep the joint stiffness favourable to the bolt.

Use multi-material design and topology and gauge optimisation while balancing crash, stiffness and NVH targets.

Run explicit dynamics crash simulation against regulatory load cases, then confirm with physical crash tests.

Allow for differential expansion with clearances, slotted holes or compliant joints.

Limit the strain below the material fatigue limit, use generous radii and validate with cyclic testing.

Compare predicted and measured stress or deflection at instrumented points and refine the model assumptions and mesh.

Use tuned structures where stiff load paths carry normal loads and dedicated zones deform in a crash.

Root-cause with field data and FMEA, redesign the weak feature, validate it, and apply change control.

Use shell elements for thin walls and solids for thick regions, with correct thickness and connections.

Apply GD&T to control only the functional features and assign the widest tolerance the function allows.

Identify the source frequency, check clearances and fasteners, then add stiffness, damping or isolation.

Question each feature function, remove or simplify non-value features and re-validate against requirements.

Balance uniform walls and draft for moulding with ribs and gussets for stiffness, then run mould-flow and structural simulation.

Use statistical tolerancing, capable processes and design features that absorb variation.

Separate dissimilar metals with coatings or isolators and control the electrolyte exposure.

Vary the key parameters systematically to find their effect and the optimum combination efficiently.

Prioritise high-risk validations, use simulation early and run critical physical tests in parallel.

Apply DFM and DFA, reduce operations and tolerances, consolidate parts and consider alternative processes or materials.

Gather requirements, run DFMEA, build the CAD model, do CAE analysis and a DFM review, prototype and run validation testing, then release with control documents.

Designs, develops and tests electric vehicle systems such as batteries, motors and power electronics.

A vehicle driven by one or more electric motors using energy stored in a battery.

A cell is the basic unit; modules group cells; a pack groups modules into the full battery.

A rechargeable battery using lithium ions, common in EVs for its high energy density.

A Battery Management System, which monitors and protects the battery.

The remaining charge in a battery as a percentage of its capacity.

The battery current capacity relative to when it was new.

Kilowatt-hour, the unit of battery energy capacity.

To convert electrical energy into mechanical motion to drive the wheels.

Recovering kinetic energy during braking and storing it back in the battery.

A device that converts DC from the battery into AC for the motor.

It steps the high-voltage battery down to power the 12V systems.

It converts AC grid power to DC to charge the battery.

AC charging uses the on-board charger; DC fast charging feeds the battery directly.

A defined plug and protocol such as CCS, CHAdeMO or Type 2.

The distance the vehicle can travel on a full charge.

A driver worry about running out of charge before reaching a charger.

A unit of power that indicates motor output or charging rate.

The traction circuit operating at hundreds of volts to drive the motor.

High voltage can be lethal, so isolation, interlocks and procedures are essential.

Controlling the temperature of the battery, motor and electronics for performance and safety.

A Permanent Magnet Synchronous Motor, common in EVs for high efficiency.

A brushless DC motor that is efficient and low maintenance.

An AC motor without permanent magnets that is robust and cost-effective.

The energy stored per unit of mass or volume.

Its typical operating voltage, about 3.6 to 3.7 volts.

An uncontrolled rise in battery temperature that can cause a fire.

A hybrid uses an engine plus a motor; a battery EV uses only electric power.

One full charge and discharge of a battery.

The charge or discharge rate relative to the battery capacity.

A safety circuit that disables high voltage if a connector is opened.

To connect or disconnect the high-voltage battery from the system.

Energy is total capacity in kWh; power is the rate of delivery in kW.

A protective device that breaks the circuit during a fault.

Equalising the charge across cells for safety and full usable capacity.

The system of battery, power electronics and motor that drives the vehicle.

The ratio of mechanical output power to electrical input power.

To remove heat and keep cells within a safe temperature range.

A common AC charging connector used in many regions.

Zero tailpipe emissions, high efficiency, low running cost and instant torque.

It monitors voltage, current and temperature, balances the cells and limits charge and discharge to safe limits.

Through coulomb counting and voltage-based models, often combined with a Kalman filter.

Calendar ageing, high temperature, deep cycling and high charge rates.

The motor acts as a generator, converting kinetic energy to electrical energy fed back to the battery.

Limits from battery acceptance, motor capacity and the need for friction braking at low speed and high deceleration.

By varying the frequency and amplitude of the AC using pulse-width modulation.

A method that controls motor torque and flux independently for smooth, efficient operation.

For their high efficiency, power density and good torque, despite the magnet cost.

DC bypasses the on-board charger and feeds the battery directly at high power.

Cell chemistry, temperature, state of charge and thermal management; high rates cause heat and degradation.

It is the power profile during charging, which drops at higher state of charge to protect the cells.

It heats or cools the cells to keep them in the optimal temperature band for power and life.

Contactors connect the pack and the pre-charge limits inrush current to protect the system.

De-energise per procedure, verify zero voltage, use insulated PPE and tools and follow lockout.

Liquid cooling is more effective and uniform; air cooling is simpler and cheaper but limited.

Passive bleeds energy from high cells; active transfers energy between cells.

An internal short, overcharge or overheating; mitigated by BMS limits, cooling and pack design and venting.

Divide the usable energy in kWh by the consumption in kWh per kilometre.

Cold weather, high speed, HVAC use, terrain and aggressive driving.

It rectifies and conditions AC grid power into controlled DC for the battery, managed by the BMS.

It powers the 12V network and accessories from the high-voltage battery.

PMSM is more efficient; induction avoids magnets and is robust and cheaper but slightly less efficient.

Electric motors produce maximum torque from zero speed without a clutch or gears.

It detects loss of isolation between the HV system and chassis to prevent a shock hazard.

Run controlled charge and discharge cycles and measure capacity, internal resistance and balance.

A conductor that connects cells and modules to carry high current.

NMC offers higher energy density; LFP offers better safety, life and cost.

Typically over the CAN bus, sharing state of charge, limits, faults and temperatures.

A contactor stuck closed keeps the HV live, so the system must detect and respond to it.

Reduce mass and drag, improve motor and inverter efficiency and optimise thermal and regen strategies.

Onboard AC charging uses the vehicle charger; offboard DC charging converts power externally.

A blending controller uses regen first and adds friction braking as needed for the total demand.

To limit inrush current to the inverter capacitors when the high voltage is connected.

Measure state of health and consumption, check thermal behaviour and rule out driving and HVAC factors.

Standards such as the IEC charging standards and the ISO 26262 functional-safety framework.

Use liquid cooling sized for peak heat, even flow distribution and BMS-controlled charge limits by temperature.

Track capacity fade and resistance growth, model degradation against cycles and temperature, and project to the end-of-life threshold.

It detects abnormal cell behaviour, isolates the pack and controls cooling, while the design adds thermal barriers and venting.

Reduce mass and drag, improve drivetrain efficiency, optimise thermal and regen and tune the control strategies.

Reducing the magnetic flux lets the motor run above base speed at constant power.

Use insulation monitoring, isolate sections, measure resistance to chassis and locate the leakage path safely.

Trade chemistry, pack design and thermal and BMS controls against the application risk and range needs.

Define the safety goals and ASIL, do hazard analysis, design safety mechanisms and verify with tests and fault injection.

Follow a temperature and state-of-charge dependent charging curve that limits current to keep cells safe.

Map the losses in the battery, inverter, motor and gearing, then improve the largest contributors.

Check the balancing function, cell matching, temperature gradients and any weak or high-resistance cells.

Coordinate regen and hydraulic braking smoothly while respecting battery limits, ABS and a consistent pedal feel.

Pre-condition and heat the pack, limit charge and discharge until warm, and manage range expectations.

Optimise the switching frequency, use suitable semiconductors such as silicon carbide and improve layout and filtering.

Errors cause range and protection issues; they are minimised with sensor accuracy, model calibration and filtering.

Include insulation monitoring, interlocks, contactors with pre-charge, fusing and clear service de-energisation.

Match the motor type and pack voltage to the torque, power and efficiency needs while controlling cost and packaging.

Analyse usage data, charging habits, temperatures and state-of-health trends to find and address the cause.

Match cell resistance, design low-impedance busbars and monitor for imbalance.

Model consumption from mass, drag, rolling resistance, drivetrain efficiency and a drive cycle, then verify on test.

Detect it via voltage and current checks, alert the driver and follow a controlled safe-state procedure.

Better cooling allows higher charge rates with less heat and degradation, extending battery life.

Use balancing where justified, monitor per-cell data over CAN and balance during charge and rest.

Weigh charging speed, cost, grid impact and use case to set the supported charging strategy.

Define requirements, select the battery, motor and electronics architecture, model and simulate, validate components and integration, and verify safety and performance.

Briefly cover your education, key projects or skills and your career interest.

Share your genuine interest and aptitude for it.

Express your passion for vehicles and the scope of the industry.

Give relevant strengths and one weakness you are improving.

Name one subject and explain your interest in it.

Briefly explain the problem, your role and the outcome.

Show basic research on its products and field.

Highlight your eagerness to learn, energy and adaptability.

Show ambition to grow within the company.

Yes, with a clear growth mindset.

Give realistic short-term and long-term goals.

Answer honestly based on your situation.

Give a modest, market-appropriate range for a fresher.

Yes, with a college or project example.

Stay calm and organised and ask for help when needed.

Share an academic or personal accomplishment.

List relevant tools such as CAD or MS Office.

Confirm based on the role requirements.

Describe any internship or training briefly.

Learning, growth and contributing to the team.

Through reading, online courses and following industry news.

Petrol uses spark ignition; diesel uses compression ignition.

An engine that completes intake, compression, power and exhaust over two crank revolutions.

A turning or twisting force produced by the engine.

A unit that measures an engine power output.

To vary speed and torque between the engine and the wheels.

To engage and disengage engine power for gear changes.

The newton.

Mass is the quantity of matter; weight is the force of gravity on it.

A force that resists relative motion between surfaces.

To start the engine and power the electricals.

Mention the learning opportunity and the company reputation.

Learn from them and work to improve.

Share relevant activities that show useful traits.

Yes, and you are willing to keep improving.

Yes, about the role, training or growth.

A 2-stroke completes a cycle in one revolution; a 4-stroke in two.

To lubricate, cool and clean the engine parts.

To slow or stop the vehicle through friction.

Yes, while staying productive.

Practical application of concepts and teamwork.

Match your skills and attitude to the role.

Accept it positively and improve.

Learning, growth and the chance to contribute.

To generate electricity and charge the battery while the engine runs.

Describe the objective, your approach, the tools used, your contribution and the result.

Share a specific challenge and how you solved it.

Give an example that connects theory to practical work.

Highlight your unique strengths, projects and learning attitude.

Through hands-on work, training and continuous learning.

Use STAR to describe your role and the outcome.

Research it, ask seniors and learn quickly.

Strength resists failure; stiffness resists deformation.

Stress is force per unit area; strain is deformation per unit length.

Spur, helical, bevel and worm gears.

Coolant circulates to absorb heat and releases it through the radiator.

Pedal force is transmitted through fluid to apply the brakes, based on Pascal law.

SI uses spark ignition for petrol; CI uses compression ignition for diesel.

It allows the driven wheels to turn at different speeds during a turn.

Stay disciplined, adapt to processes and learn from colleagues.

It forces more air into the engine for more power using exhaust energy.

Plan, prioritise and communicate your progress.

Casting pours molten metal into a mould; forging shapes metal under pressure.

Inertia, force equals mass times acceleration, and action and reaction.

Through certifications, projects and industry exposure.

Share leading a team, event or project.

Heat flows from hot to cold, and no process is perfectly efficient.

Be respectful, eager to learn and proactive.

Scalars have magnitude only; vectors have magnitude and direction.

Mention hands-on, tool and teamwork skills.

To absorb shocks and keep the tyres in contact with the road.

Bring energy, learn fast and support the team.

An AC motor runs on alternating current; a DC motor on direct current.

Focus on your learning goals and progress.

A 2D drawing shows flat views; a 3D model represents volume and space.

Admit it, learn from it and correct it quickly.

To reduce harmful exhaust emissions.

By deadline and importance.

Power is the rate of energy use; energy is the total work capacity.

Because vehicles are built through coordinated, multi-skill effort.

Accept the feedback gracefully and refine the idea.

Practical constraints, iteration and teamwork.

Learn on the job and ask for guidance.

To store rotational energy and smooth out engine power delivery.

Learn the work, support the team and steadily take on ownership.

Identify a real technical or teamwork challenge and how you overcame it.

Break it down, research, experiment and consult seniors.

Show your potential, loyalty, adaptability and lack of legacy habits.

Stay calm, prepare well, ask questions and learn fast.

Use a simple analogy that shows clear communication.

Break it down, seek guidance and persist without giving up.

Share your reasoning respectfully and defer to evidence and experience.

Mention EVs, automation and sustainability and your eagerness to contribute.

Clarify the priorities, plan and communicate.

Acknowledge the practical gap and explain your plan to learn on the job.

Stay positive, master the basics and show readiness for more.

Show humility and a corrective, learning response.

Double-check your work, follow standards and seek review.

Frame it around growth and learning while showing you intend to commit.

Connect your personal interest, projects and goals to the role authentically.

Give a brief summary of your background, key skills and what you are looking for, tailored to the role.

Connect your skills and interests to the specific role and company.

Name two or three relevant strengths, each with a brief example.

Mention a genuine, non-critical weakness and how you are working to improve it.

Summarise how your skills and attitude meet their needs better than others.

Show realistic ambition aligned with growing within the company.

Give a positive, forward-looking reason and never criticise your employer.

Show that you have researched its products, values and market.

Give a researched range and indicate that you are flexible.

Yes, supported by a brief example of collaborating successfully.

Describe staying organised, prioritising and keeping calm.

Mention growth, achievement, helping others or solving problems.

Yes, with a short example of delivering on time.

Share genuine interests, ideally ones that show useful traits.

Both, depending on the task, with a balanced explanation.

State the source honestly, such as a job portal, referral or the company site.

Share a specific accomplishment and the impact it had.

Answer honestly based on your situation.

Give your notice period or availability.

Yes, ask about the role, team or growth opportunities.

Choose three positive, relevant traits and briefly justify them.

Describe one that matches the company culture.

Accept it positively and use it to improve.

Show clear, realistic ambitions linked to the role.

Explain it honestly and positively, noting what you did during it.

Highlight a distinctive skill or quality relevant to the job.

Describe ranking tasks by urgency and importance.

Confirm based on the stated schedule.

Mention positive aspects such as learning or teamwork.

Use lists, planners, tools and clear priorities.

State it honestly.

Briefly summarise your relevant qualifications.

Share positive, credible traits.

Give realistic goals connected to the role.

Yes, with a growth mindset and an example.

Plan, prioritise and stay focused.

Mention respect, growth, teamwork or fair management.

Describe meeting goals and growing while adding value.

Explain your genuine interest and suitability.

Yes, with an example of taking ownership.

Emphasise consistency and dependability.

Mention learning, contribution and growth.

Confirm and show that you thrive on clear goals.

Name one key strength and back it with an example.

Yes, with a short supporting example.

Use the STAR method to describe the situation, your action and the positive outcome.

Share a real failure, take accountability and explain the lesson you applied.

Describe staying calm, prioritising and delivering the result.

Describe your role in a successful team effort and the result.

Share when you took initiative and guided others toward a goal.

Explain the situation, your reasoning and the outcome.

Listen, share your view respectfully and align on the shared goal.

Give an example of extra effort and the impact it had.

Describe the problem and your innovative solution.

Stay professional, communicate clearly and keep the focus on work.

Explain prioritising by deadline and importance.

Show that you accepted it and improved.

Set mini-goals and focus on quality and personal growth.

Explain the planning and focus that delivered on time.

Share an example of adjusting positively to a change.

Describe the goal, your plan and the result.

Own it, fix it and prevent it from recurring.

Show patience, empathy and a successful resolution.

Follow it while raising your concern through the proper channels.

Learn quickly, ask questions and give your best effort.

Communicate early, re-prioritise and find a workable solution.

Plan well so you deliver good work on time.

Describe how you used facts and empathy to convince them.

Be willing when needed while managing your balance.

Explain the inefficiency you spotted and your improvement.

Stay flexible and re-plan calmly.

Admit it honestly and find out promptly.

Clarify the priorities with them to align.

Share when you acted without being asked and the result.

Stay engaged through goals and self-improvement.

Stay calm, learn fast and seek guidance.

Address it appropriately or escalate it responsibly.

Be approachable, helpful and a good listener.

Describe the planning that maximised your productivity.

Listen, stay calm and resolve it professionally.

Prioritise and communicate clearly about your capacity.

Through training, feedback and taking on new challenges.

Show accountability and a constructive response.

Be clear, listen actively and confirm understanding.

Learn the role, build relationships and start adding value.

Frame each move as growth-driven and show your commitment to staying now.

Stay composed, focus on solutions and take the lessons forward.

Highlight your attitude, adaptability, fresh perspective and fit.

Voice it respectfully once, then commit to and support the decision.

Use STAR to show resilience and problem-solving.

Seek feedback, keep performing and discuss a clear path forward.

State your range and your openness to negotiate on the overall package.

Show honesty, empathy and a constructive approach.

Build trust by delivering reliably and communicating proactively.

No, and explain how you would handle such conflicts ethically and professionally.

Seek clarity, make reasonable assumptions and keep stakeholders informed.

Describe a calculated risk, your reasoning and the outcome.

Stay professional, set boundaries and escalate if it continues.

Show a growth mindset and willingness to learn from the attempt.

Connect your genuine motivations and research directly to this exact role.

Keeps plant and equipment running reliably through maintenance, repair and improvement.

Scheduled maintenance carried out to prevent failures.

Repairing equipment only after it has failed.

Using condition data to predict and prevent failures before they happen.

Preventive is based on time or usage; predictive is based on actual equipment condition.

Total Productive Maintenance, a system to maximise equipment effectiveness with everyone involved.

Overall Equipment Effectiveness, equal to Availability times Performance times Quality.

Mean Time Between Failures, the average time between breakdowns.

Mean Time To Repair, the average time to restore equipment after a failure.

Tracking equipment parameters such as vibration and temperature to detect problems.

It reduces friction, wear and heat in moving parts.

A component that supports rotation and reduces friction between moving parts.

Detecting faults such as imbalance, misalignment and bearing wear.

Using infrared imaging to detect overheating in equipment.

A system that uses pressurised fluid to transmit power.

A system that uses compressed air to transmit power.

A Programmable Logic Controller used to automate machine control.

A stock of parts kept to repair equipment quickly.

A plan of when each maintenance task is to be performed.

A document that authorises and records a maintenance job.

A Computerised Maintenance Management System for planning and tracking maintenance.

Time during which equipment is not available for production.

Finding the underlying cause of a failure to prevent its recurrence.

Lockout and Tagout, a safety procedure to isolate energy before maintenance.

Operators performing basic cleaning, inspection and minor upkeep of their equipment.

Setting two shafts in line to reduce vibration and wear.

A drive that transmits power between pulleys using a belt.

Maintenance done to correct a fault and restore function.

The way in which a component or system fails.

An electrically operated switch used in control circuits.

A heavy-duty switch used to control motors and large electrical loads.

A condition of excessive current, or the device that protects a motor from it.

The recommended time or run-hours between lubrication of a component.

To measure the pressure in a hydraulic or pneumatic system.

A measurable indicator of maintenance performance such as OEE or MTBF.

Major maintenance performed while equipment is intentionally stopped.

Planned is scheduled in advance; unplanned responds to an unexpected failure.

To maximise equipment availability and reliability at optimal cost.

A diagnostic message indicating a detected fault in a controlled system.

To transmit power and change speed or torque between shafts.

Multiply Availability by Performance by Quality; for example 92% x 95% x 99% is about 86.5%.

MTBF is total operating time divided by number of failures; MTTR is total repair time divided by number of repairs.

Availability equals MTBF divided by the sum of MTBF and MTTR.

Autonomous and planned maintenance, focused improvement, quality maintenance, early equipment management, training, safety and office TPM.

Identify critical equipment, define tasks and intervals from manuals and history, plan resources and track completion.

A method that selects the right maintenance strategy based on each failure consequence.

Base it on criticality, failure consequence, cost and downtime impact.

Imbalance shows a one-times running-speed peak; misalignment shows strong two-times and axial vibration.

Possible lubrication failure, overloading or bearing wear.

Check the pump condition, relief-valve setting, leaks, fluid level and clogged filters.

Check air pressure, leaks, restricted lines, flow controls and seal wear.

Check the load, bearings, voltage, winding condition and the overload setting.

It detects wear metals, contamination and degradation to predict component condition.

Strengthen PM and PdM, improve spares availability, train operators and do root-cause analysis.

Stock based on criticality and lead time, set minimum and maximum levels and review usage.

MTBF is the average failure interval; reliability is the probability of running without failure for a period.

Use dial gauges or laser alignment to bring shafts true; misalignment causes vibration and bearing and seal failures.

Check load, lubrication, alignment, mounting and contamination, then correct the root cause.

Train operators to clean, inspect and do basic upkeep using standards and checklists.

Multiply downtime hours by lost production value plus repair and consequential costs.

Ranking equipment by the impact of its failure to focus maintenance effort.

Look for abnormal hot spots relative to similar components or to ambient.

Back up programs, check I/O and wiring, monitor faults and keep firmware and spares ready.

Preventive may replace good parts early; predictive maximises life but needs monitoring investment.

Make it safe, diagnose, repair or bypass to restore production, then root-cause to prevent recurrence.

It plans, schedules and records work orders, history, spares and KPIs.

Optimise PM frequency, adopt predictive methods, reduce breakdowns and improve spares management.

Identifying failure modes and effects to plan the right maintenance tasks.

Schedule maintenance in planned slots, coordinate with production and use predictive timing.

A failure-rate curve with high early failures, a low random-failure middle and rising wear-out.

Compare repair cost, remaining life, reliability, downtime and replacement cost.

Tighten connections, check insulation, do thermography, clean panels and test protection devices.

Monitor OEE, MTBF, MTTR, PM compliance and downtime, then act on the worst metrics.

It increases friction and heat, leading to wear, overheating and seizure.

Apply LOTO, use PPE, follow permits and verify zero energy before starting.

Define functions and failures, analyse consequences, select the right tasks, then implement and review.

Audit PM quality, do root-cause on the failure history, check for design or operating causes and adjust the strategy.

Analyse the failure distribution such as Weibull to choose intervals that minimise total cost and risk.

Improve diagnostics, spares readiness, repair procedures, training and equipment accessibility.

Monitor pressure and flow under load and check relief valves, internal leakage and pump performance at temperature.

Select critical assets, set baselines and alarm limits, schedule routes, trend data and act on alerts.

Look for gear-mesh frequencies and sidebands indicating tooth wear plus bearing fault frequencies.

Quantify avoided downtime, extended component life and fewer breakdowns against the monitoring cost.

Check shaft currents, lubrication, alignment, load and contamination, then correct the true cause.

Cut breakdowns with PdM and TPM, reduce micro-stops and changeover losses and address quality-related stops.

Classify by criticality and lead time, use min-max or order policies, and pool or standardise parts.

Plan the scope and schedule, sequence tasks and resources, manage safety and contractors, and control time and cost.

Contain it, root-cause with a formal method, add engineering controls and procedures, and verify effectiveness.

Capture sensor and process data, trend it against failures and use analytics to predict and prevent breakdowns.

Base it on the failure pattern: random failures favour condition-based; predictable wear favours time-based.

Fix leaks, correct alignment and lubrication, maintain motors and drives and tune compressed-air systems.

Track completion rates, audit task quality, link PM to failure reduction and refine the tasks.

Check power quality, I/O and sensor signals, wiring and grounding, and log events to catch the trigger.

Identify the top failures by cost and downtime, root-cause them and apply targeted reliability fixes.

Keep critical skills in-house, outsource specialised or peak work, and manage contractor quality and safety.

Track total spend against replacement value, benchmark it and reduce breakdowns and waste.

Address the operating practice and controls, train operators, and add protection or alarms.

Capture maintainability and reliability requirements early, set up PM and spares, and feed back launch issues.

Set alarm and trip thresholds, watch the rate of change and plan intervention before the limit.

Stabilise with strong PM and 5S, build criticality-based PdM, train staff, adopt a CMMS and continuously improve the KPIs.

Plans, optimises and oversees manufacturing processes to produce goods efficiently.

A sequence of workstations where a product is built up progressively.

The time taken to complete one unit at a process.

Available production time divided by customer demand, the pace required to meet demand.

The total time from order to delivery of the product.

The number of units produced in a given period.

The slowest process step that limits the overall output.

Work In Progress, the partially completed units in the system.

A philosophy of eliminating waste to maximise customer value.

Overproduction, waiting, transport, over-processing, inventory, motion, defects and unused talent.

Sort, Set in order, Shine, Standardise and Sustain, a workplace organisation method.

Continuous incremental improvement involving everyone.

Producing or supplying only what is needed, when it is needed, in the quantity needed.

Bill of Materials, the list of parts and components needed to make a product.

A plan of what to produce, how much and when.

Overall Equipment Effectiveness, equal to Availability times Performance times Quality.

A jig guides the cutting tool; a fixture holds the workpiece in position.

A bar chart that shows tasks against time for scheduling.

Batch makes groups of items; continuous runs an uninterrupted flow.

High-volume manufacture of standardised products.

A documented step-by-step instruction for performing a task consistently.

Scheduled maintenance carried out to prevent breakdowns.

Time during which a machine or line is not producing due to a stoppage.

A signal or card system that controls material flow and replenishment.

Mistake-proofing, designing a process to prevent errors.

To move material or products between workstations.

Moving, storing and controlling materials within production.

The maximum output a process or plant can produce.

The ratio of actual output to the maximum capacity.

Material that is rejected and cannot be reworked.

Correcting a defective product to make it acceptable.

Production is the output quantity; productivity is output per unit of input.

Enterprise Resource Planning software that integrates business and manufacturing processes.

An instruction that authorises production of a specific job or quantity.

Distributing work evenly across stations to minimise idle time.

Process, product, fixed-position and cellular layouts.

A Computer Numerical Control machine that produces parts from programmed instructions.

Using machines and controls to perform tasks with minimal human intervention.

To deliver the right quantity and quality at the right time and at minimum cost.

A small-scale run to validate the process, tooling and quality before full production.

Multiply Availability by Performance by Quality; for example 90% x 95% x 98% is about 83.8%.

Measure cycle times to find the slowest constrained step, then add capacity, balance the load or reduce its workload.

Push produces to a forecast; pull produces to actual downstream demand using Kanban.

By minimising idle time and matching station times to takt, which improves utilisation and throughput.

A visual map of material and information flow used to expose waste and improve flow.

Plan, Do, Check and Act, an iterative method for continuous improvement.

Single-Minute Exchange of Dies, reducing changeover time to enable smaller batches.

Convert internal setup to external, standardise tooling and use quick-clamp fixtures.

It reduces movement and WIP and improves flow and operator flexibility.

Available time divided by demand; for example 27,000 seconds for 450 units gives 60 seconds per unit.

Manage the system around its single biggest constraint to maximise throughput.

A tool used to level production by volume and product mix.

Less stock cuts carrying cost but leaves little buffer against supplier delays.

It defines the process controls, checks and reactions that keep quality in specification.

Track and eliminate micro-stops through autonomous maintenance, root-cause fixes and TPM.

A measure of how well a process fits within tolerance; a higher value means a more capable and centred process.

Re-balance lines to the new takt, add shifts or overtime, debottleneck and coordinate with supply chain.

MRP plans material requirements; ERP is broader, integrating finance, HR, sales and production.

Apply pull and Kanban, balance the stations, reduce batch sizes and improve flow.

To visualise and reduce excessive movement of people and material.

Availability loss is downtime and stops; performance loss is running slower than the ideal cycle.

Compare volume, cost, quality consistency, flexibility and payback or ROI.

Total task time divided by stations times cycle time; a higher value means less idle time.

Prioritise by demand and margin, run the constraint efficiently, outsource overflow and schedule maintenance off-peak.

A documented best-known method that ensures consistency and provides a baseline for improvement.

Use root-cause analysis, poka-yoke, operator training and in-process checks.

Optimise the trade-offs to the customer priority while improving processes to lift all three.

Operators perform basic cleaning, inspection and minor upkeep of their own equipment.

Estimate demand, takt, process times and machine and manpower needs, and allow for ramp-up.

Cycle time is how fast you produce; takt is how fast you must produce to meet demand.

Improve the Kanban and replenishment system and supplier reliability, and buffer critical items.

A small inventory before the constraint to keep it from being starved.

Track output per labour hour and improve it through method study, balancing and training.

Designing the product and process together shortens launch time and reduces rework.

The percentage of units that pass through without rework or scrap on the first attempt.

Break the work into tasks, balance them to 40 seconds or less per station, size the buffers and plan tooling and manpower with capacity margin.

Measure the six big losses, attack the largest which is often availability, apply TPM, SMED and quality fixes, then sustain with standards.

Identify the constraint, exploit it, subordinate everything to it, elevate it, then repeat without letting inertia set in.

Balance setup cost against inventory holding cost using EOQ logic while honouring flow and quality goals.

Use a dynamic constraint approach, scheduling by mix, balancing loads and adding flexible capacity.

Quantify labour, quality, throughput and scrap savings against the cost, then compute payback and ROI or NPV.

Observe and break the task into elements, time them, rate the operator, then add allowances to set the standard time.

Sequence the models to level the workload using Heijunka and balance stations for the combined task content.

Form a team, contain it, find the root cause with an Ishikawa diagram and 5-Why, fix it permanently, verify and standardise.

Build the pillars such as autonomous and planned maintenance, focused improvement and education, and track OEE.

Stabilise process parameters, train operators, mistake-proof the process, run SPC and tackle the top defects first.

Map the current state, cut waiting and WIP, apply flow and pull, and design a future state with FIFO lanes and supermarkets.

Compare cost, capacity, quality, intellectual property, lead time and strategic risk.

Sample periodically, plot X-bar and R charts, react to out-of-control signals and keep the capability index acceptable.

Debottleneck, balance the lines, add shifts, reduce changeover with SMED and outsource the peaks.

Place a buffer before the constraint to protect it and a shipping buffer to protect the due dates.

Capture machine data for real-time OEE, predictive maintenance and bottleneck and quality analytics.

Improve supplier capability, use milk-runs and Kanban, dual-source critical parts and right-size the buffers.

Multiply each stage yield together, then improve the weakest stages first through root-cause analysis and poka-yoke.

Overlap the capacity, run a pilot, transfer demand gradually and validate quality before the full switch.

Audit consumption, eliminate idle running, optimise compressed air and HVAC, and recover or reuse where possible.

Use lean to remove waste rather than value, keep the controls and standards, and never compromise safety.

Use supermarkets where flow cannot be continuous and FIFO lanes to sequence between disconnected processes.

Find the sources of variation across method, machine, operator and material, standardise them, and remove special causes.

Identify the loss, quantify the baseline, run DMAIC or PDCA, validate the savings, then standardise and control to sustain them.

Ensures products and processes meet quality standards and continuously improve.

Inspecting and testing products to detect defects.

Building processes to prevent defects and ensure quality.

QA is proactive and process-focused; QC is reactive and product-focused.

A non-conformance to a requirement or specification.

A documented requirement that a product or process must meet.

The permissible variation in a dimension or property.

Examining a product against its requirements.

A failure to meet a specified requirement.

Comparing an instrument to a standard to ensure its accuracy.

Measuring internal and external dimensions and depth accurately.

Precise measurement of small dimensions such as thickness or diameter.

A pass or fail gauge that checks whether a part is within limits.

A graph that monitors process variation over time.

A list used to verify that all required checks have been done.

Finding the underlying cause of a problem rather than just the symptoms.

Asking why repeatedly until the root cause is reached.

A cause-and-effect diagram that groups potential causes.

Failure Mode and Effects Analysis, identifying and prioritising potential failures.

A document listing the process controls used to maintain quality.

Statistical Process Control, using statistics to monitor and control a process.

A data-driven method to reduce defects to about 3.4 per million opportunities.

Define, Measure, Analyze, Improve and Control.

A bar chart that shows the frequency distribution of data.

A chart that ranks causes by frequency, based on the 80/20 rule.

Roughly 80% of problems come from 20% of the causes.

Inspecting a representative sample instead of every unit.

Acceptable Quality Level, the worst tolerable average quality in a sampling plan.

Corrective And Preventive Action.

Rework corrects a defect; scrap is discarded.

The ability to track a product history, location and components.

A systematic check of compliance with standards or procedures.

An international quality management system standard.

The automotive quality management system standard.

Production Part Approval Process, proving a supplier can make parts to requirements.

Advanced Product Quality Planning, a structured product and process development framework.

A study of measurement system repeatability and reproducibility.

Accuracy is closeness to the true value; precision is repeatability and consistency.

Coordinate Measuring Machine, used for precise 3D dimensional measurement.

A top-level document that describes the quality management system.

Cp measures the spread against tolerance; Cpk also accounts for how centred the process is.

Typically 1.33 or higher, which indicates a capable process with low defect risk.

Form a team, define and contain the problem, find the root cause, take corrective action, validate, prevent recurrence and close out.

Common cause is inherent and random; special cause is assignable to a specific source.

Points beyond the limits, trends, runs or non-random patterns indicate a special cause.

Items such as design records, FMEA, control plan, MSA, capability studies, samples and the part submission warrant.

Planning, product design, process design, product and process validation, and feedback and improvement.

Several operators measure several parts multiple times, then the repeatability and reproducibility variation is analysed.

Under about 10% is good; 10 to 30% may be acceptable depending on the application.

List the functions, failure modes, effects, causes and controls, then score severity, occurrence and detection and prioritise.

Risk Priority Number, equal to Severity times Occurrence times Detection.

A control plan defines what to control and how; a work instruction tells the operator how to do the task.

Contain or sort the stock, run a root-cause 8D, implement CAPA and communicate with supporting evidence.

The cost from defects, including scrap, rework, warranty, returns and lost reputation.

Prevention, appraisal, internal failure and external failure costs.

Use a standard such as ANSI/ASQ Z1.4 based on lot size, inspection level and AQL.

Measurement System Analysis, which ensures data is reliable before it is used for decisions.

Run a gauge R&R and check the method, training, gauge condition and standardise the procedure.

Sampling is cheaper and faster but risks acceptance error; 100% catches more but costs more.

Tally defect types by frequency, sort them in descending order and plot bars with a cumulative percentage line.

The defined actions to take when a characteristic goes out of control.

Process FMEA addresses process failures; Design FMEA addresses product or design failures.

Calibrate it and run an MSA covering bias, linearity and gauge R&R.

A checkpoint where parts must meet criteria before they can proceed.

Use lot or serial coding and keep records of material, process and inspection at each stage.

Frequent multi-level checks on key process steps to sustain the standards.

Raise an NCR, contain it, find the root cause, implement CAPA and verify effectiveness.

Corrective action fixes an existing problem; preventive action stops a potential one.

Use Cpk against the single specification limit.

A run chart plots data over time; a control chart adds statistical control limits.

Clarify the requirement, agree the controlling specification and document it through change control.

It verifies that the first produced part meets every drawing requirement before mass production.

Define the problem, measure the baseline, analyse the root causes, improve, then control to sustain the gains.

The maximum defects allowed to accept a lot versus the count that causes rejection.

Through incoming inspection, supplier PPAP, certificates of analysis and supplier audits.

Appoint a champion and team, contain shipped stock with interim action, find the technical and escape root cause, apply a permanent fix, validate it, prevent it systemically and recognise the team.

The spread is fine but the mean is off-target, so adjust the process centre and then re-verify Cpk.

Choose the sample size and acceptance number so the OC curve gives acceptable producer risk at AQL and consumer risk at LTPD.

Run the APQP phases, require the PPAP elements, audit the process, verify capability and approve through the part submission warrant.

Stratify the data, use MSA to rule out gauge error, then study process variation and the conditions present when it occurs.

Define the CTQ, confirm the measurement system, select the chart type, set limits from stable data, train operators and react to signals.

Reduce variation through process improvement, centre the mean, or add sorting or 100% inspection as an interim measure.

Compare the two measurement systems, re-measure jointly, review the specification and disposition the lot using data.

Count the defects per opportunity, scale them to a million to get DPMO, then convert that to a sigma level.

Analyse field data with Pareto, strengthen the DFMEA and PFMEA, improve the controls and feed lessons back to design.

Bias is the offset from true, linearity is bias across the range and stability is drift over time, each assessed against standards.

Use action priority or RPN weighted by severity, tackling high-severity items with weak detection first.

Define the key checks, schedule multi-level audits, track findings, escalate non-compliance and close the loop.

Confirm the root cause was addressed, monitor the data over time and verify there is no recurrence under the original conditions.

Transform the data or use non-normal capability methods such as a Weibull or percentile-based index.

Make the wrong assembly physically impossible or trigger an immediate detection or alarm.

Assess the impact, update the FMEA and control plan, validate the change and require approval or PPAP before release.

Use scatter plots and regression to quantify the relationship and then set control limits on the parameter.

Use dedicated certified sorting before shipment, clear marking and daily reporting until the permanent fix is verified.

Cpk uses within-subgroup short-term variation; Ppk uses overall long-term variation and performance.

Quantify the failure and appraisal costs, model the reduction from prevention and show the net savings or ROI.

Escalate through supplier development, controlled shipping levels, on-site audits or re-sourcing.

Use hypothesis testing such as a t-test or ANOVA to compare before and after at a chosen confidence level.

Capture in-line measurements into a system for live SPC, alarms and traceability dashboards.

Use DFMEA in design, APQP in planning, PFMEA and a control plan in the process, and MSA and SPC in production, with feedback loops throughout.

Identifies customer needs, presents suitable products, handles objections and closes sales while building relationships.

Good listening, product knowledge, confidence, empathy, persistence and honesty.

Prospecting, which is finding and qualifying potential customers.

Prospecting, approach, needs assessment, presentation, objection handling, closing and follow-up.

Finding and identifying potential customers or leads.

A potential customer who has shown some interest.

Contacting a prospect who has had no prior interaction with you.

Encouraging a customer to buy a higher-value or upgraded product.

Offering related or complementary products alongside the main purchase.

Customer Relationship Management software used to track leads, customers and follow-ups.

A feature is what the product has; a benefit is what it does for the customer.

It builds trust and lets you match the right vehicle to the customer needs.

To let the customer experience the vehicle and build emotional buying interest.

Getting the customer to commit to the purchase.

Staying in contact with prospects and customers to convert and retain them.

A set goal of sales to be achieved within a period.

Supporting customers before, during and after the sale.

Warmly and promptly, introducing yourself and offering help without pressure.

A friendly, trusting relationship with the customer.

A concern or reason a customer gives for not buying.

Price or budget.

The upfront amount a customer pays toward a vehicle.

Equated Monthly Instalment, a fixed monthly loan repayment.

A loan arrangement that lets a customer pay for a vehicle over time.

Exchanging a customer old vehicle as part-payment for a new one.

Service, maintenance and support provided after the purchase.

A manufacturer promise to repair or replace defects within a set period.

It helps you understand needs and recommend the right product.

It conveys confidence and helps you read the customer interest.

A new customer recommended by an existing one.

Stay calm, listen, empathise and focus on solving their concern.

A persuasive presentation of a product to a customer.

B2B sells to businesses; B2C sells to individual consumers.

A written statement of the price and terms offered to a customer.

Keeping existing customers loyal and buying again.

A sign that the customer is ready or close to buying.

A customer tendency to keep buying the same brand.

Set goals, celebrate wins, learn from rejection and stay positive.

A demonstration of the product features to the customer.

It builds long-term trust and repeat business.

Another company selling similar products to the same customers.

A reduction in price offered to encourage a purchase.

To meet targets while keeping customers satisfied and loyal.

It reassures the customer and makes the pitch convincing.

The display area where vehicles are presented to customers.

Acknowledge it, reinforce the value and benefits, compare total cost of ownership and offer finance options.

Find the real concern, summarise the value and agree a clear next step or follow-up.

Ask open questions about usage, budget, family size and preferences before recommending.

Translate each feature into what it does for the customer, such as safety, savings or comfort.

Acknowledge their research, highlight your unique strengths and value rather than criticising rivals.

Tie the driving experience to their needs, address any concerns and move toward a buying decision.

The assumptive close, alternative-choice close, summary close and urgency-based close.

Recommend genuinely relevant upgrades that add value to their stated needs.

Show options within budget, explain financing and focus on value rather than only discount.

Be warm, listen, find common ground and show genuine interest.

Add value with each contact, respect their timeline and agree the next touchpoint.

Reinforce value first, offer non-price incentives and discount only within your limits.

Break down the down-payment, tenure, monthly instalment and total cost simply.

Treat it as feedback, stay positive and keep prospecting.

Qualify by interest, budget, need and timeline, then focus on the hottest ones.

Log every interaction, set follow-up reminders and track the pipeline.

Selling actively creates value and persuades; order-taking just processes a known request.

Acknowledge it, apologise on behalf of the brand and rebuild trust through action.

Highlight genuine limited offers, stock or timing without false pressure.

Narrow the options, reassure them and guide with a clear recommendation.

Know your limits, defend value, trade concessions and aim for a win-win.

Resolve it well to build loyalty and earn referrals.

Study brochures, attend trainings and track competitor models.

Break targets into daily activity, track progress and adjust your effort.

Through referrals, follow-ups, social media, events and database calling.

Check their budget, authority, need and timeline.

Acknowledge each one, set expectations and manage your time fairly.

Focus on what you do offer and the overall value, and suggest alternatives.

Highlight reliability, resale value, warranty and peace of mind.

Emphasise quality, reliability, service and the total cost of ownership.

Reach out with a new offer, a relevant update or a helpful reason to reconnect.

Respect the friend input and answer their technical questions confidently.

Keep prospecting while closing, so new leads replace converted ones.

Suggest relevant accessories that genuinely enhance the customer experience.

Plan your activity, stay consistent and avoid pushy tactics that hurt trust.

Follow up with value, check for concerns and offer help to decide.

Read their needs and personality and adjust your tone, focus and pace.

Explain current offers and availability while respecting their choice.

Track conversion rate, average deal value, targets met and customer satisfaction.

Follow up, ensure smooth delivery and service and stay reachable.

Re-qualify the pipeline, prioritise hot leads, revive past prospects and increase high-value activity.

Quickly reaffirm value, seek an approved concession or add-on and secure commitment.

Stay calm, explain your limits, involve a manager if justified and protect the margin.

Deliver great service, ask satisfied customers for referrals and recognise or reward them.

Lead with value, total cost of ownership, financing and emotional benefits rather than price alone.

Own it, fix it fast, compensate fairly and follow up to rebuild trust.

Refuse to mislead and sell honestly to protect the customer and long-term reputation.

Review lead quality, your pitch, follow-up, pricing and competitor activity to find the cause.

Map the decision-makers, nurture relationships, address each need and keep momentum to close.

Balance both but weight your effort by expected value and likelihood of conversion.

Be honest about the limits, offer the best feasible alternative and manage expectations.

Be transparent, back claims with facts and let them verify, positioning yourself as an advisor.

Use pipeline stage, conversion history and seasonality to project realistic numbers.

Differentiate on value and service, protect key customers and avoid a pure price war.

Maintain a full pipeline, keep sharpening your skills, leverage referrals and follow a disciplined daily process.

Converts fuel energy into mechanical energy to drive the wheels.

Cools the engine coolant by dissipating heat to the surrounding air.

Lubricates moving parts, reduces friction and wear, and helps cool and clean the engine.

A component that ignites the air-fuel mixture in a petrol engine combustion chamber.

Engages and disengages engine power to the gearbox so gears can be changed.

Petrol uses spark ignition; diesel uses compression ignition.

Stores electrical energy to start the engine and run electricals when the engine is off.

Generates electricity to charge the battery and run electricals while the engine runs.

To slow or stop the vehicle by converting kinetic energy into heat through friction.

Disc brakes and drum brakes.

The grooved rubber pattern that grips the road and channels away water.

With a gauge when tyres are cold, compared against the manufacturer specification.

To absorb road shocks and keep the tyres in contact with the road for comfort and control.

A damper that controls spring movement to reduce bouncing.

To clean the air entering the engine, preventing dust and grit from causing wear.

To remove dirt and impurities from fuel before it reaches the engine.

A fluid that regulates engine temperature and prevents freezing or overheating.

Revolutions per minute, how many times the crankshaft turns each minute.

The system that transfers engine power to the wheels at different speed and torque ratios.

Manual needs the driver to shift gears using a clutch; automatic shifts gears itself.

Adjusting wheel angles to specification for even tyre wear and straight tracking.

Adding weights so a wheel and tyre rotate without vibration.

To carry away and quieten burnt gases and reduce emissions.

An exhaust device that converts harmful gases into less harmful ones.

Anti-lock Braking System.

To tighten fasteners to a specified torque value.

Measuring voltage, current and resistance in electrical circuits.

To synchronise the rotation of the crankshaft and camshaft.

To circulate coolant through the engine and radiator.

A valve that regulates coolant flow based on engine temperature.

A safety device that breaks the circuit during excess current to protect components.

The recommended distance or time between scheduled maintenance.

Abnormal combustion that produces a knocking or pinging sound.

Maintains system pressure and raises the boiling point of the coolant.

A service is scheduled preventive maintenance; a repair fixes a specific fault.

To check the engine oil level.

To drive accessories such as the alternator, water pump and AC compressor.

Old oil loses lubrication quality and collects contaminants, leading to engine wear.

To illuminate the road and make the vehicle visible at night.

To warn other road users with an audible signal.

Intake, compression, power and exhaust strokes complete one combustion cycle over two crankshaft revolutions.

MPFI injects fuel into the intake port; direct injection sprays fuel straight into the cylinder.

Low coolant, a faulty thermostat, a failed water pump, a blocked radiator or a broken fan.

On-Board Diagnostics II, a standard port and system to read fault codes and live engine data.

Check fuel supply, spark or ignition, and ECU and sensor inputs systematically.

Check battery charge, terminals, starter motor, ignition switch and fuses.

Misalignment, imbalance, incorrect pressure or worn suspension components.

To recirculate some exhaust gas into the intake, lowering combustion temperature and NOx.

Random or multiple cylinder misfire.

Open the bleeder valves to expel air while topping up fluid, because air makes the pedal spongy.

Air in the lines, low fluid, worn pads or a failing master cylinder.

Sensors detect wheel lock and the modulator rapidly pulses brake pressure to keep grip.

It measures exhaust oxygen so the ECU can fine-tune the air-fuel ratio.

About 14.7 to 1 by mass.

Measure with a feeler gauge at TDC and adjust shims or tappets to specification.

Coolant entering combustion from a head gasket fault, or briefly condensation on a cold start.

Engine oil burning in the combustion chamber from worn rings or valve seals.

A rich mixture, meaning too much fuel or too little air.

It uses exhaust gas to spin a compressor that forces more air in for more power.

The delay before the turbo spools up and delivers boost.

A high-pressure rail feeds electronically controlled injectors for precise multiple injections.

Independent lets each wheel move separately; a rigid axle links both wheels together.

Measure battery voltage with the engine running; about 13.8 to 14.5 volts indicates charging.

Current draw with everything switched off; it is traced by measuring current and pulling fuses.

To vent crankcase blow-by gases back into the intake, reducing emissions and pressure.

Uneven pad wear, a stuck caliper or a hydraulic imbalance.

Wheel imbalance, a bent rim or worn suspension and steering parts.

It allows the driven wheels to rotate at different speeds while turning.

Hydraulic uses a pump and fluid pressure; electric uses a motor for assistance.

It measures intake air mass so the ECU can meter the correct amount of fuel.

Connect to the OBD-II port and monitor parameters such as RPM, coolant temperature, fuel trims and sensor outputs.

A protective state where the ECU limits performance after detecting a fault.

Short-term is instant correction; long-term is the learned average adjustment.

Connect the positives first, then negative to a ground point on the dead car, start it, then remove leads in reverse.

Oil and filter change, fluid levels, brakes, tyres, belts, lights and a diagnostics scan.

Check fuel pressure and delivery under load, coil and plug condition, and intake leaks; log freeze-frame data and fuel trims.

Look for coolant loss, white smoke, oil-coolant mixing and overheating, then confirm with a combustion-leak test or compression and leak-down test.

Apply compressed air to a cylinder at TDC; air escaping into the intake, exhaust, crankcase or coolant pinpoints valve, ring or gasket faults.

Check tyre pressure, air and fuel filters, oxygen sensor ageing, fuel trims, dragging brakes and driving pattern.

Faulty glow plugs, low compression, injector timing or leakage, or low-cetane fuel.

Reproduce the conditions, wiggle-test harnesses, check grounds and connectors, and monitor voltage drop across the circuit.

Under load it reveals high-resistance connections that a no-load continuity test would miss.

Inspect caliper slide pins, piston seizure, rotor condition, driving habits and pad quality.

Likely a failing cooling fan or fan clutch, since airflow is lost at low speed.

Check OBD port power and ground, the CAN bus wiring and module power, and look for a shorted module on the bus.

Run a compression and leak-down test, check the PCV, inspect valve seals and check the turbo seals.

It indicates a lean condition; suspect vacuum or intake leaks, weak fuel delivery or a faulty MAF.

A diesel particulate filter traps soot and regenerates by burning it; short trips and faults prevent regeneration and clog it.

Via a scan tool under safe conditions when passive and active regeneration fail and soot load is high.

Measure key-off current after modules sleep, pull fuses one by one to isolate the circuit, then test the component.

Check fluid level and condition, scan for codes, test line pressure and assess clutch and band wear.

Excess heat, low octane, a lean mix, carbon or wrong timing; correct fuel quality, cooling and timing and clean carbon.

Use a smoke machine on the EVAP system and inspect the gas cap, purge and vent valves and lines.

Test warm with the throttle open; readings should be within about ten percent of each other.

Scan the ABS module codes and check wheel-speed sensors, tone rings, wiring and the module.

Read hybrid system codes, check high-voltage battery state of health, cooling and the inverter, while observing HV safety.

Check refrigerant charge, compressor clutch cycling, condenser airflow, pressure switches and electrical control.

De-energise per manufacturer steps, use insulated PPE and tools, verify zero voltage and follow lockout.

Monitor live data for misfire counts and check the IAC or throttle body, vacuum leaks, injector balance and ignition.

Do not just clear codes; identify the failing component using freeze-frame data, live data and pinpoint tests, then verify the repair under the original conditions.

Oversees daily workshop operations, technicians, workflow, quality and safety to deliver timely service.

A document recording the customer vehicle, requested work, parts and labour.

To track the work, parts, time and approvals for each vehicle.

A designated workspace where a vehicle is serviced or repaired.

The sequence of steps a vehicle passes through from reception to delivery.

The ratio of hours actually worked on jobs to the hours available.

The ratio of standard or flagged hours to the actual hours taken.

A vehicle returning for the same issue that was not fixed properly.

Redoing a job that was not done correctly the first time.

Personal Protective Equipment such as gloves, goggles and safety shoes.

Sort, Set in order, Shine, Standardise and Sustain, for an organised workspace.

Scheduled upkeep of tools and machines to avoid breakdowns.

An approximate cost of parts and labour given to the customer.

A measure of how satisfied customers are with the service.

Repairs that are covered under the manufacturer warranty.

To liaise between the customer and the workshop on requirements and updates.

The stock of spare parts kept for repairs.

A controlled store for workshop tools and equipment.

To raise a vehicle for underbody work.

It improves safety, efficiency and the customer impression.

A list that ensures all service steps are completed.

Time when a bay or technician is idle or unable to work.

To enforce safety rules, PPE use and hazard control.

Assigning jobs to technicians based on skill and workload.

A check before delivery to ensure the work is done correctly.

It builds customer trust and satisfaction.

Anything that can cause injury or damage, such as spills or live wires.

Technicians and staff coordinating to complete jobs efficiently.

A request to issue parts from the store for a job.

To keep technicians skilled and updated on new vehicles.

A plan of which vehicles are serviced and when.

The number of vehicles serviced in a given period.

To tighten fasteners to the correct specification.

A unit of time charged for a technician work.

To put out small fires and protect staff and property.

It tracks history, warranty, parts and accountability.

Keeping the area clean, organised and free of hazards.

A concern raised about service quality or experience.

To lead technicians and oversee jobs on the floor.

To deliver quality service on time, safely and profitably.

Match each job to the right skill level, balance the workload and consider deadlines.

Reduce idle time, ensure parts and tools are available and balance the workload.

Enforce quality checks, root-cause the issues, train technicians and inspect before delivery.

Identify the cause, reallocate resources, inform the customer and recover the schedule.

Prioritise jobs, balance bays and technicians and stagger appointments.

Enforce PPE, conduct checks, train staff and control hazards.

Check stock, expedite procurement, use approved alternatives and update the customer.

Listen, investigate, resolve the issue and follow up to rebuild trust.

Use checklists, standard procedures, final inspection and technician accountability.

Recognise good work, set clear goals, give feedback and support their development.

Address it privately, hear both sides and resolve it fairly and professionally.

Sort and remove clutter, organise tools, clean, standardise and sustain it with audits.

Monitor productivity, efficiency, comebacks, throughput and CSI, then act on the gaps.

Identify the cause, coach or train them, set expectations and monitor improvement.

Diagnose properly, list the parts and labour and add any contingencies clearly.

Improve diagnosis, parts readiness, workflow and bay utilisation.

Verify coverage, document properly and follow the manufacturer process.

Schedule preventive maintenance, track usage and replace worn tools.

Use standard procedures and checks so work is both fast and correct.

Make the area safe, give first aid, report it and prevent recurrence.

Diagnose it, inform the customer, get approval and update the estimate.

Provide SOPs, train them, supervise and audit the work quality.

Track jobs, productivity, pending work and issues, and report to management.

Extend capacity, prioritise, schedule well and communicate timelines.

Improve scheduling, parts readiness and quick job allocation.

Train staff, standardise the entries and verify completeness before closing.

Stay calm, listen, empathise and focus on a solution.

Orient them, assign a mentor, train them on procedures and monitor progress.

Standardise procedures, do inspections and track comebacks per technician.

Analyse demand, set reorder levels and coordinate with the parts department.

Use seat and floor covers, follow handling rules and inspect before and after.

Balance coverage with the workload and stagger leaves to maintain capacity.

Plan the day, prioritise, allocate well and avoid cutting quality.

Track it, root-cause the failures and improve diagnosis and training.

Set clear rules, lead by example and address issues consistently.

Streamline workflow, ensure parts readiness, balance bays, improve diagnosis and keep quality checks.

Coach on quality, enforce inspections and tie performance to first-time-fix rather than just speed.

Secure the scene, give aid, investigate the root cause, fix the hazard and retrain staff.

Review the job card and evidence, explain the work calmly and resolve it fairly.

Analyse idle time, parts delays and skill gaps, then fix the biggest losses systematically.

Prioritise transparently, allocate skilled staff, communicate timelines and avoid neglecting others.

Reroute affected jobs, arrange repair or a backup, communicate delays and adjust the schedule.

Counsel and document it, retrain them and escalate to disciplinary action if it continues.

Root-cause the defects, strengthen checks and training and hold technicians accountable.

Deliver quality and value efficiently so that satisfied customers drive repeat, profitable business.

Use data and testing to resolve it objectively, involving an expert if needed.

Tie incentives to first-time-fix and CSI, not just hours, to protect quality.

Reprioritise, redistribute the work, use overtime or support and manage customer expectations.

Analyse the cases and check the procedures, parts and skills, then correct the root cause.

Take ownership, investigate fully, resolve it and report the corrective action.

Improve communication, on-time delivery, quality and consistent follow-up.

Tighten control and accountability, investigate and act per policy.

Schedule by job type and duration and avoid bottlenecks at shared resources.

Advise the customer honestly with the options and let them decide.

Plan structured training and certification with hands-on practice and a strong safety focus.

Increase capacity sustainably without overloading staff or skipping checks.

Cut rework, idle time and waste while improving productivity and parts management.

Balance them with clear communication and decisions that protect quality and trust.

Define the standards, checklists, inspection points, comeback tracking and accountability.

Plan and allocate the work, ensure parts and safety, monitor quality and KPIs, handle customers well and continuously improve.