The process of roll forming involves sheet metal feed through a sequence of rollers, each of which imparts a specific shape to the metal. These rollers collaborate to produce the desired cross-section. Because of its consistency with ease of repetition, rolling is an excellent method for efficiently producing huge quantities of metal parts. Roll forming enables production for long components with intricate cross-sections from sheet materials that exhibit high strength. This paper aims to develop a fundamental understanding of the effect of control factors such as roll load at entry and exit, roll speed roller diameter, temperature of rollers, bending pressure, percentage reduction in thickness of roll sheet on final shape in the roll formed parts by using Taguchi’s method of process optimization. This study aimed at enhancing the quality characteristic of roll forming process, by optimizing some roll forming process parameters using the Taguchi method. Also, the effect of process parameters in roll forming of mild steel has been investigated. To analyze how roll forming process parameters affect final shape of the roll formed sheet, an orthogonal array, principal effect analysis, signal-to-noise ratio are applied. Results indicate that the optimal conditions for minimizing shape geometry of roll formed sheet include an entry and exit load, roll speed, no. of pass and such others. Additionally, the Taguchi method for Design of experiments (DOE) is used to explore significant effects, including interactions among roll forming process.