Schefenacker Vision System Australia Pty Ltd (SVSA) is one of 30 companies in the Schefenacker International group, which is the leader in rear vision mirror manufacturer with a 30 percent market share of the world market. SVSA in Adelaide employs over 600 people and the turnover for 2005 was 178 MAUD. This thesis project came about since Schefenacker in Adelaide was going to produce the rear vision mirror for the new Ford Super Duty Truck 2008, with code name P356. Schefenacker desired an optimal material handling process for this complex P356 production. This resulted in cooperation with the University of South Australia and Luleå University of Technology in Sweden and this master thesis project arose. Focus has been put on what could be done in a near future since it felt important to have recommendations that could be put into practice within the close proximity of launch and production. Great importance has been on integrating the employees’ opinions into the development and result of this process. A project cycle method was developed to carry out this thesis work, since it was necessary with a primary method which could manage a constant flow of new information. The model was developed with inspiration from the Deming wheel: plan, do, act and learn, together with Ranhagen’s spiral model: a process should precede several laps before finish. The philosophy Lean thinking has played an important roll throughout the process. Qualitative facts are the base of this project. The information was gathered through literature studies, a questionnaire, observations and interviews with concerned workforce. The survey questionnaire was carried out in the assembly area of the P356 mirror’s predecessor P131. The result from the P131 study has been working as a foundation during the entire project. The authors have been guided for comprehension about which areas improvements would be desirable. The result is also presented in an individual report, consisting of recommendations on how a more efficient production and a better work environment can be achieved at the P131 area. Benchmarking studies at Electrolux, Mitsubishi, Holden and Philmac have been carried out which resulted in greater comprehension of different possibilities concerning material handling. A Specification of requirements for an optimal material handling process with belonging layout was developed. Different layout alternatives with diverse agendas were developed and later on compared. This resulted in a final layout proposal combined of two alternatives, with core focus on safety, minimised material handling and quality issues. In the thesis suggestions can be find about of how and where to store material for the P356 production, which quantities to hold, efficient transportation solutions, other improvement concepts and some warnings concerning future hazard risks in the work environment. Several analysis concerning the material handling processes and the work environment such as NIOSH have been made. According to the authors current buggy runs should be standardised and integrated with supplying the production systems. Dedicated trolleys should be used within the system acting as storage since they are space efficient and prevents double material handling. The developed prototype concept “Ball table trolley” could be an asset in the material handling process, if developed further, according to the thesis authors. The thesis is most useful for Schefenacker but can also contribute to other companies within the automotive industry and in other industries. The thesis could be helpful when planning an optimised material handling process, planning the division of parts, planning methods of replenishing parts and other aspects which are important when implementing a new production and optimising an existing process. Hopefully will this thesis trigger questions and create ideas when planning or analysing other material handling processes.