Abstract : Most of countries start to restrict the emission gases of vehicles especially CO2 because of the global warming. Many vehicle companies including Toyota have launched various HEVs to satisfy the restriction laws and to improve the vehicle’s efficiency. However, development for heavy-duty hybrid system is not plentiful rather than the passenger car. In this study, we choose the optimal size of engine, motor and battery for heavy-duty hybrid systems using dynamic programming. Also we analyze the correlation of the system’s cost and efficiency because the added cost of vehicle to make the hybrid system is very important factor for the manufacturing companies. Finally, this study suggests a method to choose the appropriate system components size considering its performance and the cost. With this method, it is possible to select the component size for various systems.