Motherson Sumi Design Engineer Interview: Rounds, Questions and Preparation

What the job involves

A Design Engineer in manufacturing and automotive sectors creates 3D CAD models, 2D drawings, and design specifications for components and assemblies. They work on new product development, design modifications, and cost reduction while ensuring manufacturability, quality, and compliance with industry standards. Day to day involves using CAD software, performing tolerance analysis, collaborating with manufacturing and suppliers, and supporting prototype builds and testing.

Role and Technical Knowledge

1. 1

   Explain GD&T and its importance in automotive design.

   Define GD&T as a system to specify allowable variations, mention key symbols like flatness and position, and highlight how it ensures interchangeability and reduces manufacturing costs.

2. 2

   What factors do you consider when selecting a material for a car interior component?

   Discuss mechanical properties, durability, weight, cost, manufacturability, aesthetic requirements, and compliance with automotive standards like flammability and VOC emissions.

3. 3

   How would you perform a tolerance stack-up analysis for an assembly?

   Explain worst-case and statistical methods, identify critical dimensions, and show how to calculate total variation to ensure fit and function.

4. 4

   What is DFMA and how have you applied it in a project?

   Define DFMA as design for manufacturing and assembly, give an example like reducing part count or simplifying geometry, and mention benefits like lower cost and faster assembly.

Practical Scenarios

1. 5

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

   Outline a structured root cause analysis using tools like 8D or fishbone, check design calculations, material specs, and manufacturing defects, then propose design changes and validate.

2. 6

   You need to reduce the weight of an existing bracket without compromising strength. What steps would you take?

   Suggest topology optimization, material substitution, or ribbing, and mention using FEA to validate strength and considering manufacturing constraints.

3. 7

   How would you handle a situation where a supplier cannot meet the tolerances specified in your drawing?

   Discuss reviewing the tolerance stack-up, possibly relaxing non-critical tolerances, collaborating with the supplier on process improvements, and updating documentation with approvals.

4. 8

   Describe how you would create a 3D model and drawing for a simple automotive clip.

   Mention sketching, extruding, adding features like snaps, applying draft angles, then creating a drawing with proper views, dimensions, GD&T, and title block.

Behavioural and HR

1. 9

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

   Use STAR method: describe the project, your role, how you collaborated, and the outcome. Highlight communication and conflict resolution if applicable.

2. 10

   Why do you want to work in the automotive manufacturing sector?

   Show passion for automobiles, mention the dynamic nature of the industry, and connect your skills to contributing to innovative, safe, and sustainable vehicles.

3. 11

   How do you prioritize tasks when you have multiple deadlines?

   Explain using urgency and importance, breaking tasks into smaller steps, communicating with stakeholders, and using tools like to-do lists or project management software.

4. 12

   Are you willing to relocate or work in a manufacturing plant environment?

   Be honest and positive, express adaptability, and emphasize eagerness to gain hands-on experience and learn from the shop floor.

Company and Industry Awareness

1. 13

   What do you know about our company and its products?

   Research the company's key products, clients, and global presence. Mention specific examples like automotive interior or exterior components and recent innovations.

2. 14

   What are the current trends in automotive design and manufacturing?

   Discuss lightweighting, electric vehicles, autonomous driving, sustainability, and smart manufacturing. Relate how design engineers contribute to these trends.

3. 15

   How does your academic background prepare you for this role?

   Connect coursework in CAD, mechanics, and materials to job requirements. Mention projects, internships, or certifications that demonstrate relevant skills.

4. 16

   Where do you see yourself in five years?

   Show ambition to grow into a senior design or lead role, emphasize continuous learning, and express commitment to contributing to the company's success.