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The processes utilized in building-up and installing automotive door assemblies to a body are required to address a complex interaction of dimensional requirements. The Dimensional Management Process is employed to arrive at the optimum design and process to achieve the many functional and appearance related requirements of the door system. This paper will demonstrate the application of the Dimensional Management Process to the typical automotive door system and the use of integrated three-dimensional tolerance analysis to compare different door assembly and installation methods for the purpose of achieving an optimum appearance and functionality of the door system.