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This paper presents the most recent advancement in the vehicle development process using the one-step or auto Transfer Path Analysis (TPA) in conjunction with the superelement, component mode synthesis, and automated multi-level substructuring techniques. The goal is to identify the possible ways of energy transfer from the various sources of excitation through numerous interfaces to given target locations. The full vehicle model, consists of superelements, has been validated with the detailed system model for all loadcases. The forces/loads can be from rotating components, powertrain, transfer case, chain drives, pumps, prop-shaft, differential, tire-wheel unbalance, road input, etc., and the receiver can be at driver/passenger ears, steering column/wheel, seats, etc. The traditional TPA involves two solver runs, and can be fairly complex to setup in order to ensure that the results from the two runs are consistent with subcases properly labeled as input to the TPA utility.

There are various optimization tools available on the market and they are successfully used for improving vehicle component designs in terms of performance and light weight [6][7][9][10]. But when it comes to full vehicle optimization, optimization tools are only one aspect of the entire process. To build up a FEM Model for NVH analysis the assembly process and load case definition play an important role. Both steps are very complex and the chance to make mistakes is very high. After initial analysis the results has to be interpreted to understand the NVH behavior and detect optimization potential. Diagnostic tools could be used to determine modal or panel participation factors or do transfer path analysis. Then components or subsystems could be optimized using numerical optimization tools. For this step often super elements are used to reduce calculation time without losing too much of accuracy.