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In this paper the emphasis is on the applications of DFMA in automotive electrical and electronic systems. This sector seems to have been neglected as a fertile area for DFMA applications. In these systems DFMA goes further into the optimization of processes for the manufacture, assembly and installation of electrical components and units. This paper provides a new approach to the DFMA process by demonstrating its applicability to electrical and electronic systems in the automotive industry. The case studies reported in this paper include the improvement of the assembly plant installation process and sequencing of the a. Airbag Electronic Control Module (AECM), b. Power Distribution Center with minimum impact on tooling schedule, c. Instrument Panel Wiring Harness and d. Electrical Distribution Wiring (EDW). The other case studies that focus on electromechanical systems include the e. Transmission System Selection Indicator ( PRNDL) and f. Overhead Console.