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The Finite Element Analysis (FEA) is widely used in automotive industry for many applications, such as structural analysis, computational fluid dynamics (CFD), vibration behavior and acoustic properties, crashworthiness and, more recently, manufacturing process simulation. For all these FEA applications, accuracy is always a key issue. The analysis accuracy depends mainly on two factors: on one hand the FEA codes and on the other hand the definition of boundary conditions and material properties. Over the years, most FEA codes are well tested for accuracy through numerous benchmarks: therefore breakthroughs in further accuracy improvement from the aspect of FEA codes are difficult to achieve. On the other aspect, there is some room for FEA improvement by means of more accurate definition of material properties. In this paper, a new methodology for improving analysis accuracy by considering thickness variations of the component is proposed and validated using a structural body part.