The automotive industry is a highly competitive market characterised by low profit margins or huge losses. Cost reductions have been of top priority for all OEM’s (Original Equipment Manufacturer) and will continue to be so for many years to come. Beside cost reductions, reducing the time-to-market is of greatest importance to stay in the competition. OEM’s that are slow to market with products that neither matches customer expectations nor the products of their competitors, will soon loose market shares and see their economical performance falter. Therefore, it is of major importance for the OEM’s to shorten their product development time and at the same time reduce costs.Special packaging has a significant impact on the logistical system and production cost of a car. The development process of re-designing or implementing special packaging is a very complex process and extends over a considerable time period. Therefore, the aim of the thesis is to provide the PED (Packaging Engineering Department) with suggestions for an improved development process of special packaging ensuring the most cost efficient packaging is used. To fulfil the aim, the exploratory research method was used where we took part in the development process of re-designing a new special packaging for headlining. Parallel to that work, a literature study was carried out. Theories and models from the literature study together with data and information gathering from the development process of special packaging for headlining constitute the basis for the result and the new development process for special packaging.The result of the thesis is concluded in three major parts. First of all, the development process must be lift out from the car projects. The development process should instead be performed in an annual process were the concept of the most cost efficient special packaging is being developed and predefined already at the car project start. Secondly, the logistics must be more actively involved in the early phases of the car projects. Thirdly, the lessons learned process must be highlighted in the organisation and be much better utilised. Finally, this redeployment work is something that must be started by the PED as soon as possible. It must be done to cope with the future with closer between pre-series and where more car projects will be running parallel at the same time. The need for a more cost efficient material flow and a rapid development process will also be even more evident than today. This will require an extensive and hard work from the annual process group before this new way of working with packaging development will work efficiently. Therefore, the sooner the annual process group is establish and starts working, the easier it will be to cope with the future and the better the performance of the PED will be. / Uppsatsnivå: D