In the Roll-to-Roll (R2R) system, the design and development for a roller path and control system are mainly performed by the expert’s experience. There are some important issues in the numerical analysis method of R2R system. This study proposes an efficient R2R system analysis method. The first one is the Approximated Winding Length Estimation (AWLE) algorithm which can calculate the analytic winded length of the workpiece. The core winder is approximated with line and arc segments in this algorithm. As a result, in the numerical model of R2R system, we can replace the winder characteristics with the approximated winding length estimation (AWLE) algorithm. The second one is the contact algorithm between workpiece and rollers. This contact algorithm must be stable and fast for precise analysis. The third one is the flexible workpiece model. The workpiece can be modeled by the finite elements. By implementing these some important issues, this paper proposes an efficient R2R system analysis method.