Variations in vehicle noise, vibration and harshness (NVH) response from one vehicle to the next can have significant impact on an automotive company’s profile and profitability. The warranty claims due to excessive NVH response end up costing the manufacturers a large sum of money each year. In addition, the OEM will suffer a larger financial loss due to the poor perception of quality and customer dissatisfaction with their products due to the unacceptable NVH response. Therefore, measures must be taken to ensure less warranty claims and higher levels of customer satisfaction. This research focuses on aspects of design variations that are costly or difficult to be avoided in the design process such as variations with rubber parts and variations due to rotating components. Vibrations induced at the tire/wheel assembly due to variations in the radial and tangential forces and radial runout are responsible for the driver-felt vibrations that can lead to a large number of warranty claims. The purpose of this research is to improve the process of determining and analyzing vibration sources in the tire/wheel assembly in order to benefit the automotive manufacturer during the development and manufacturing phases. This research identifies the relationship between non-uniformity forces of the tire/wheel assemblies and the driver-felt vibrations during typical highway driving speeds. The contribution from each assembly location is analyzed and sensitivities are determined. A Monte Carlo process is used to predict numerous non-uniformity properties that are statistically representative of the assembly properties that can be expected at the manufacturing plant. The Monte Carlo produced non-uniformity properties are combined with the sensitivities to predict driver-felt vibrations that can be expected from vehicles leaving the manufacturing plant. This process provides the tools to determine an acceptable level of non-uniformities based on targets for interior vibration levels or determine if the vehicle sensitivities to non-uniformities need to be improved.