The Tata Motors Accident Research Group (TMARG) has been involved in accident data recording on the Mumbai‐Pune expressway since 2010. Analysis of accident statistics highlighted that 16% of the crashes were underrun of cars against heavy goods vehicles (HGVs) of which half were full‐width underrun and the other half were offset underrun. Eight per cent (8%) of these crashes were fatal accounting for 33% of all fatal crashes. A detailed study of the data has shown that the conventional Rear Underrun Protection Device (RUPD), as per ECE R58, is not able to stop the smaller vehicle from riding under the larger vehicle in an offset impact. Further analysis was carried out to identify the severity of impact. As a result, a new load case to simulate this kind of crash was developed through CAE‐based solutions. This paper explains the new system, its evaluation and recommendations for improvement in the rear underrun protection systems on heavy goods vehicles (HGVs).