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Automobile safety is becoming one of the important criteria for customer vehicle selection. Vehicle manufacturers have a challenging task for introducing variety of products in market in short time domain. Engineering a product for safety parameters involves many critical attributes which could affect vehicle design and styling parameters. In this context, instrument panel (hereafter referred as IP) profile, design and package are one of the aspects which affect lower extremity injuries of an occupant in a frontal crash. The occupants due to inertial properties, and shock levels move inside the passenger compartment thereby resulting into knees and lower legs contacting the IP. It is found in many cases that knee-femur injuries are higher due to improper contact area and package of hard components behind IP. This paper explains a methodology of establishing the knee impact zone using a Knowledge Based Engineering (KBE) application.