ABB India Engineering Design Engineer Interview: Rounds, Questions and Preparation

What the job involves

A Design Engineer in manufacturing, automobile, and engineering creates 3D CAD models, detailed drawings, and technical documentation for components, sub-assemblies, and products. The role involves performing engineering calculations, selecting materials and tolerances, and working with manufacturing and quality teams to ensure designs are producible and meet cost, safety, and performance targets. Day to day work includes design reviews, design for manufacturing and assembly (DFMA) improvements, and supporting prototype builds and testing.

Role and Technical Knowledge

1. 1

   What is the difference between a datum and a datum feature in GD&T, and why is it important in design?

   Explain that a datum is a theoretically exact point, axis, or plane, while a datum feature is the actual physical feature on the part. Stress that datums establish a consistent reference for measurement and assembly, reducing ambiguity in manufacturing and inspection.

2. 2

   How do you decide the tolerance for a shaft and hole fit in an assembly?

   Mention that you start from functional requirements (clearance, interference, or transition fit), then use standards like ISO 286 or ANSI B4.1. Also consider manufacturing capability, cost, and tolerance stack-up with mating parts.

3. 3

   Explain the steps you follow to create a 3D model and drawing for a new bracket.

   Describe starting with a sketch, applying constraints, extruding or revolving, adding features like holes and fillets, then creating a drawing with views, dimensions, GD&T, and a title block. Emphasize design intent and revision control.

4. 4

   What is DFMA, and how would you apply it to a sheet metal enclosure design?

   Define DFMA as designing for easy manufacturing and assembly. For sheet metal, mention reducing part count, using standard bend radii, avoiding tight tolerances, designing self-locating features, and choosing fasteners that are easy to install.

Practical Scenarios

1. 5

   A prototype part fails during testing because of a crack near a fillet. How do you investigate and redesign?

   Suggest checking stress concentration, material properties, and manufacturing defects. Then propose increasing fillet radius, changing material or heat treatment, or adding ribs. Mention validating with FEA and a revised prototype test.

2. 6

   You need to reduce the weight of an existing automotive component by 15 percent without compromising strength. What approach do you take?

   Discuss topology optimization, using higher strength-to-weight materials, thinning walls with rib reinforcements, and validating through FEA. Also consider manufacturing constraints like casting or molding draft angles.

3. 7

   During assembly, operators report that a part does not fit easily. How do you handle this as the design engineer?

   Say you would visit the assembly line, measure the actual parts, and check tolerance stack-up. Then propose design changes like chamfers, lead-ins, or looser tolerances, and update the drawing with a revision.

4. 8

   You are asked to select a material for a gear that must be lightweight and wear resistant. What factors do you consider?

   Mention mechanical properties (hardness, fatigue strength), wear resistance, density, cost, and manufacturability. Compare options like alloy steel, aluminum with hard anodizing, or engineering plastics, and justify with application loads and speed.

Behavioral and Teamwork

1. 9

   Tell me about a time you worked in a team to complete a design project. What was your role?

   Use the STAR method. Focus on your specific contribution, how you coordinated with others, and the final outcome. Highlight communication and conflict resolution if applicable.

2. 10

   Describe a situation where you had to learn a new CAD tool or engineering software quickly for a project.

   Show initiative and adaptability. Mention how you used tutorials, practice, and help from peers, and how you delivered the required design on time.

3. 11

   How do you handle criticism of your design from a senior engineer or manufacturing team?

   Emphasize listening without defensiveness, asking clarifying questions, and evaluating the feedback objectively. Give an example where you revised your design and improved the outcome.

4. 12

   Give an example of a time you managed multiple deadlines for design deliverables.

   Describe how you prioritized tasks, used tools like calendars or task lists, communicated with stakeholders, and still maintained quality. Mention any trade-offs you made.

HR and Motivation

1. 13

   Why do you want to work as a Design Engineer in the manufacturing and automobile sector?

   Connect your interest in creating tangible products, solving engineering problems, and seeing designs move to production. Mention specific aspects like precision, innovation, or sustainability in manufacturing.

2. 14

   Where do you see yourself in three to five years as a design engineer?

   Show ambition to grow into a senior design role or technical expert, with deeper skills in areas like simulation, design automation, or project leadership. Align your goals with continuous learning and contributing to the company.

3. 15

   Are you willing to relocate or work at a manufacturing plant location if required?

   Answer honestly but positively. If flexible, state your willingness and mention that hands-on exposure to production is valuable for a design engineer. If not, explain how you can still support plant teams remotely.

4. 16

   What do you know about our company's products or engineering work?

   Research the company's key products, recent innovations, and markets. Mention specific examples like electrification, automation, or automotive components, and link them to your skills and interest.