In order to improve simulate efficiency, a car door inner panel forming process scheme and process parameter sensitivity were studied by the method of feature analysis and numerical simulation combined with orthogonal experiment. The results of feature analysis show that the place of the window frame corner and groove are easy to be fractured, the place of panel angle is easy to be wrinkled, and the stiffness of window frame joint edge surface is poor. The research results of numerical simulation and orthogonal experiment show that the forming performance is improved through adjusting the process. The sensitivity order from high to low of partial process factors got by orthogonal experiment is die fillet radius, height of drawing rib, friction coefficient, blank size, blank holder force and clearance. The research results show that the process optimization based on feature analysis and the sensitivity of key parameters is an effective way for designing cover panel process.