With Ever Increasing Vehicle speed and Vehicle concentration on roads the number of accidents is also increasing. Safety and Strength of Vehicle has become a prime focus in Automobile Industry. The endeavor is to make a safe vehicle which would ensure occupants safety during collision. In Automotives, door system strength plays a vital role in defining the vehicle response during accidents. These accidents through, side door intrusion test and dynamic side impact test are simulated in the vehicle development cycle. Strength of the door required to meet these test criteria is dependent on the door beam, reinforcements, beam layout, vehicle construction and materials selected.There is not a fix method for door beam selection and design. Hence, it becomes all the more difficult to design and layout door beam and other reinforcements. In this paper we will discuss, challenges faced in a layout of door beam for a new vehicle program. Limitation in use of CAE analysis for achieving actual results, and design & layout modifications to be carried out to meet side door intrusion criteria effectively.