ACC Limited Design Engineer Interview: Rounds, Questions and Preparation

What the job involves

A Design Engineer in manufacturing and engineering works on creating, modifying, and optimising product designs, components, and systems using CAD software and engineering principles. They collaborate with production, quality, and procurement teams to ensure designs are manufacturable, cost-effective, and meet industry standards. Day to day involves preparing drawings, performing calculations, running simulations, and resolving design issues on the shop floor or with vendors.

Role and Technical Knowledge

1. 1

   What is GD&T and why is it important in design engineering?

   Explain Geometric Dimensioning and Tolerancing, its role in communicating design intent, reducing ambiguity, and ensuring interchangeability in manufacturing.

2. 2

   How do you decide between using a bolted joint and a welded joint in a design?

   Discuss factors like load type, disassembly needs, material compatibility, cost, and strength requirements, with examples from machinery or structures.

3. 3

   What are the key considerations when designing for manufacturing (DFM)?

   Cover simplifying designs, minimising parts, choosing suitable processes, tolerances, and material availability to reduce cost and lead time.

4. 4

   Explain the difference between a fit and a tolerance in engineering drawing.

   Clarify that tolerance is allowable variation in a dimension, while fit is the relationship between mating parts (clearance, interference, transition) based on tolerances.

Practical Scenarios

1. 5

   A component you designed fails during prototype testing. How do you approach the failure analysis?

   Outline steps: gather data, inspect failure mode, check calculations, review material and manufacturing, use FEA if needed, and propose design changes with validation.

2. 6

   Production reports that a part is difficult to assemble on the line. What do you do?

   Discuss visiting the line, understanding the issue, reviewing design for assembly, simplifying features, adding chamfers or guides, and coordinating with production for trials.

3. 7

   You need to reduce the weight of an existing bracket without compromising strength. How would you proceed?

   Mention analysing load paths, using FEA to identify low-stress areas, optimising topology, changing material to higher strength-to-weight ratio, and validating with testing.

4. 8

   How would you handle a situation where a vendor suggests a design change to reduce cost?

   Explain evaluating the change for functionality, safety, and compliance, discussing with cross-functional teams, and if viable, updating drawings and documentation through change control.

Behavioural and HR

1. 9

   Tell us about a time you worked in a team to complete a design project.

   Use STAR method: describe project, your role, collaboration, challenges, and outcome. Highlight communication and conflict resolution.

2. 10

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

   Show passion for creating tangible products, interest in continuous improvement, and awareness of sector challenges like cost, quality, and innovation.

3. 11

   How do you handle criticism of your design from senior engineers?

   Demonstrate openness, focus on learning, asking questions, and using feedback to improve the design rather than taking it personally.

4. 12

   Are you willing to relocate or work in plant locations?

   Be honest and flexible; express willingness to adapt to company needs and eagerness to gain hands-on experience.

Company and Sector Awareness

1. 13

   What do you know about our company's product lines or recent projects?

   Research the company's products, markets, and recent news. Relate your skills to their design needs, showing genuine interest.

2. 14

   What are the current trends in manufacturing design, such as Industry 4.0 or sustainable design?

   Discuss automation, IoT, digital twins, lightweight materials, energy efficiency, and how design engineers contribute to these trends.

3. 15

   How can a design engineer contribute to cost reduction in a manufacturing company?

   Mention value engineering, standardisation, material substitution, process optimisation, and reducing complexity without sacrificing quality.

4. 16

   What safety standards or regulations should a design engineer be aware of in your industry?

   Reference relevant standards like ISO, ASTM, or BIS, and explain how they influence design decisions and testing.