The customer satisfaction index is higher for disc brake systems because of the advantages like less reaction time, shorter stopping distance and improved pedal feel compared to drum brake system. In current competitive market scenario and as per customer requirements, front disc brake module is becoming necessary.The brake system design is challenging task due to stringent performance meeting criteria and packaging constraints with weight optimization. Brake disc is very important component in the brake system which is expected to withstand high braking torque and dissipate heat during braking event. In existing car to replace front drum brake with disc brake module, vehicle needs to undergo legislative verifications and certifications with respect to pedal effort, stopping distance and circuit failed conditions etc.This paper explains development of disc brake system with novel brake disc during transition to switch from drum to disc brake with respect to packaging constraints, which has met all the performance in competitive price. In Conventional disc brake system, brake rotor has hat type construction which is complicated considering design complexity and takes higher manufacturing lead time. Innovative concept of front disc brake (Patented by Tata Motors) with straight brake rotor was evolved and later on designed with respect to packaging constraint. Number of manufacturing steps for this brake disc rotor is drastically reduced, resulted in less manufacturing time with cost & weight reduction.Digital thermal performance evaluated in house, fine-tuned and verified by correlating with test data available for existing design and then applied for new design.