The design for manufacturability process has been recognized as a very effective method for improving the overall quality in mechanical product design. The first part of the paper deals with an extended DFM which encompasses all the various Quality issues in product development. The importance of the three major elements quality, cost and timing are highlighted in the mathematical model for Design for Quality (DFQ). The second part of the paper describes the application of DFQ in the design and development of minivan body and interior systems. The best value of the DFQ is recognized when the process is used proactively during the early stages of the development cycle. Such is the case of the applications discussed in this paper which covers the following systems: hood assembly, seamless door system, sliding door system, instrument panel and message center installation, and fuel filler door-and-housing system.