1.A part that ran fine yesterday is coming off the lathe out of tolerance today. Walk me through what you do.
Why they ask
This is the core of the job. They want to hear a method, not a guess, and they want to know you'll stop the bleeding before you chase the cause.
How to answer
- Stop the machine and quarantine the suspect parts so nothing bad ships
- Check the obvious first: insert wear, a loose tool holder, chips in the collet, a changed offset
- Ask the operator what changed, including a new bar of material or a warm-up skipped after a weekend
- Measure the last good part and the first bad one to see if it's a jump or a drift
- Fix it, record the cause on the setup sheet, and decide with quality what to do with the suspect parts

