This paper presents redesign of a car body for material weight reduction for the cost saving by material as well as fuel efficiency improvement. ULSAB (Ultra Light Steel Auto Body Structure) concept is used for weight reduction in redesigning process. Modularization is used for redesigning to reduce parts cost. Four factors: cost of modules, cost of assembly, common design and weight of the car are considered. Comparison for the material cost, weight and assembly time has been done for proposed design and existing design. Redesign car shows efficient fuel consumption car. Automotive sector could reduce their total manufacturing cost per vehicle by using modularization in design. The customers will get cheaper and fuel efficient car.
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