For the side outer panel parts of a SUV vehicle, its structure characteristics and the stamping process were analyzed by Autoform numerical simulation software, and the forming process of the water trough, door frame, rear bumper overlap and tail light areas were discussed in particular. Then, the possible forming defects were predicted, and a reasonable stamping process was confirmed. The analysis results show that the water trough of the side outer panel, the pillar of the door frame and the tail light areas become wrinkling, and the risk of cracking exists at the round corner on the back door frame and rear bumper overlap. Furthermore, the forming process is optimized by enlarging the die corner at the cracking area, adjusting the blank holder force and changing the length of reinforcement rib. The trial production practice proves that wrinkling or cracking can be effectively prevented by the optimized forming process.