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Today's automotive exhaust systems are developed to deliver minimum noise, emissions and maximum durability based on the legislative and performance requirements. In addition, they must also meet requirements of packaging, safety, flow rates, lower system restriction, high temperature compatibility, corrosion resistance, easy serviceability and cost effectiveness. These challenging requirements cannot be met effectively without a systems approach. The exhaust system development process starts with selection of design methodology and evolution of checklists for system design specifications and definition of targets. System design specifications are elaborated with reference to performance, durability, legislation, installation, manufacturing / assembly / service considerations, etc. Checklists for exhaust system clearance and design review are given.