Ergonomic techniques have been required to analyze the effectiveness of functional clothing design improvement in a systematic and analytic manner. The goals of the present study are to: (1) comprehensively and analytically examine the effectiveness of clothing improvement by using the relationship analysis between clothing design components (D) and ergonomic evaluation measures (E) and (2) prove the usefulness of cost-effectiveness analysis for clothing design optimization. The cost effectiveness analysis is comprised of the preliminary evaluation based on expertise and the in-depth evaluation where the D-E relationship analysis is applied. As a result of the cost effectiveness analysis applied to flame-proof clothing, an optimal design was identified by analyzing costs and qualitative/quantitative effects. In the preliminary evaluation, the expected effectiveness of each design alternative on wear efficiency and wear comfort was estimated. In the in-depth evaluation, however, the effectiveness of each design alternative was analyzed by quantitative evaluation in a wearing test using a questionnaire prepared based on the D-E relationship analysis. It was concluded that the D-E relationship analysis and the cost-effectiveness analysis are useful for comprehensive evaluation and optimization of functional clothing design.