In this work, a cylindrical cup design is investigated for meeting the dimensional accuracy, vibro-acoustic and crash performance simultaneously. Cylindrical cup forming simulations are performed using different deep drawing process parameters—Blank Holder Force (BHF), Friction Coefficient, Blank thickness and misalignment—to predict geometric profile and thickness variations. The formed geometry is used to simulate the vibro-acoustics performance of the design. The cylindrical cup has nominal dimensions of 80 mm diameter, 24 mm deep and 0.97 mm thickness. Forming simulations are performed to quantify the vibro-acoustic variability caused by changes in process parameters. The vibro-acoustic variability is attributed to the geometry profile and thickness distribution changes of the deep drawing manufacturing process. To investigate the same, the Design Of Experiments (DOE) studies, based on Taguchi orthogonal arrays, are carried out to characterize the effect of individual process parameters on the response. The deep drawing analysis and the subsequent vibro-acoustic simulations are instrumental in optimizing both functional requirements. The crash performance of the component is predicted using the empirical formula mentioned in the literature. It is shown that a careful selection of process parameters help to optimize the response for multiple functional requirements.