The article explores the use of Model-Based Design (MBD) to develop a detailed electro-thermal (ETDM) model for the Smart Latch System (SLM) in next-generation vehicle door automation. Ensuring model accuracy is essential for enhancing design verification, validating requirements, and simulating specific failure scenarios. The article also investigates the impact of minimizing feedback branches in the engine control system to determine the optimal configuration, focusing on cost reduction. Additionally, it examines the effects of feedback anomalies from the integrated Hall effect sensor and how the microcontroller processes current feedback via a shunt resistor. Various parametric simulations assess the control system’s robustness against model uncertainties. Finally, processor-in-the-loop testing validates the operational logic and response times, facilitating rapid design adjustments, reducing prototyping time, and enhancing industrial production efficiency.