Any Automotive exhaust system is evaluated based on the following criteria, namely pass-by noise (PBN), exhaust backpressure, durability & reliability (D&R), Thermal Safety, and cost. Exhaust Aftertreatment System/Devices (EATS) has become integral to BS-IV or EU-IV onwards vehicles, which require additional emissions testing. This paper covers an innovative exhaust solution for a 17L, 780 hp engine Eu6 vehicle, having a higher exhaust gas flow rate and severe application (duty cycle), and the same packing space of exhaust upstream pipe. In addition, it was the requirement to take account of field failure issues observed in earlier products (running in the field) and to resolve problems faced during the Beta Proto Build. Authors have optimized the Design using CFD (for backpressure) , Durability analysis (Structural life), IPS simulation (for Accessibility) and Thermal simulation (hot spot analysis). The designed exhaust upstream pipe is an innovative twin-bellow configuration with thermal insulation and an anchoring mounting with chassis. All the design proposals are further drilled down using Pugh Matrix evaluation based on QDCFS (Quality, Design, Cost, Feature, Safety). Further, Design has been evaluated accessibility point of view for two aspects - design for Assembly (DFA) and Design for Serviceability (DFS) during beta Proto Build. Thermal safety evaluation is a critical event, especially at Beta Proto Build and the pre-launch production phase. It was found ok during the evaluation, and it was observed a good correlation with simulation data. This work indicates that the effectiveness of innovation and optimization based on simulations, along with QDCFS assessment, is very useful for robust design solutions. The design also satisfied the Backpressure and D&R target, even with the lesser diameter of the upstream pipe than recommended and with the double bellow rather than a conventional single bellow. Keywords: Exhaust Installation, Exhaust Pipe, Double bellow, Mounting, Optimization, Design for Serviceability, Design for Assembly, Pugh Matrix.