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Public conveyance such as a bus is a major contributor to socio - economic development of any geography. The international market for passenger bus needed to be made viable in terms of passenger comfort, minimum operational costs of the fleet by reduced fuel consumption through light weighting and yet robust enough to meet stringent safety requirements. Optimized design of bus body superstructure plays vital role in overall performance and safety, which necessitates to evaluate bus structure accurately during initial phase of design. This paper presents a robust methodology in numerical simulation for enhancing the structural characteristics of a bus body with simultaneous reduction in the weight by multi-material optimization while supplemented with sensitivity and robustness analysis. This approach ensures significant reduction in vehicle curb weight with promising design stiffness.