The development of automotive embedded software and calibrations presently involves an expensive development cycle in terms of both time and cost. A primary reason is the associated expense and time require to apply the various technologies needed for software testing and calibration development. Early in the design cycle software-in-the-loop (SIL) and Hardware-in-the-Loop (HIL) systems are typically employed. Later stages use costly engine and vehicle hardware as part of the software test and calibration development process. During this phase propulsions systems may initially utilize dynamometers and eventually migrate to vehicle level testing. All these technologies contribute to large budgets and design times required for embedded software and calibration development. Extending the capability of General Motors Virtual Manufacturing (SAE 2008-01-0288) vehicle level software testing and calibration development can now be accomplished using this enhanced statistical simulation and analysis process. This has been accomplished through the integration of embedded software and calibration into the virtual high fidelity subsystems being analyzed. The accuracy of these high fidelity subsystems coupled with statistical analysis provides an optimal method to test embedded code and develop production ready calibrations. Additionally due to Virtual Manufacturing’s comparatively low budgetary requirements significant cost savings are incurred compared to current design methodologies. Data presented in the following sections will show the advantage in terms of cost, the ability to test software, and produce production ready calibration using this enhanced Virtual Manufacturing process.