The objective of this paper is to outline a practical approach using numerical modelling and optimization techniques for process and product developments in metal cold rolled forming industry. The optimum economic viability in manufacturing industry requires a minimization of the amount of material used while the structural performance of a cold roll formed product relies on maintaining the stiffness and strength of the section in applications. This leads to the development of new cold forming processes and alternative cold roll formed profiles searching for the optimal profile. In this paper, a Finite Element modelling approach was utilized to simulating complicated manufacturing process and products and optimization techniques including Design Of Experiments was used to optimize the shape design of the end products to obtain lighter products while maintaining the product strength. These developments were illustrated through two case studies of Hadley Industries plc which included (1) numerical modelling of a novel Ultra STEEL^® cold roll forming process, and (2) optimization of cold roll forming sections.