Automotive manufacturers are facing unprecedented cost challenges across globe. Market requirement has become very competitive with increased demand for higher performance and value engineering. This is encouraging automotive manufacturers to develop dampers with local suppliers, as there is a huge component cost advantage and also logistic cost savings. However, in emerging markets, supplier capability to develop the component for solving particular NVH problem of OEM is not matured as compared to developed market suppliers. The challenge for auto makers is to develop suppliers who can provide proper performance and durability, while at the same time providing lower cost components.This paper gives an overview of the challenges in the development process to develop a competitive torsional vibration damper for rear wheel drive vehicle to reduce boom noise and vibration. It is also designed to assist local suppliers with the capability to design and develop torsional vibration damper with low cost while meeting vehicle durability and performance requirements.This paper describes: aThe methodology developed to tune the torsional vibration damper and optimize the performance for different driving condition;bA new design approach to meet the vehicle durability requirement;cA process to validate different designs for performance and durability requirements; anddA design for six sigma methodology applied in arriving at an optimized and robust solution.