<p>The roll forming process generally requires limited adjustments by the operator if the process conditions remain stable. However, in industrial environments, material parameters fluctuate more often; as a result, the product shape quality can vary, and this requires roll position adjustment to bring the product quality back to specification. In industrial production, the incoming material properties and geometric dimensions are usually not monitored continuously, and the influence of real material variation on the product’s quality is yet to be investigated. In this work, a test routine is implemented that continuously monitors the material properties and the sheet thickness of the incoming strip in an industrial roll forming line. This is combined with an inline measurement of the roll forming load and part shape quality. The experimental analysis is complemented with finite element analysis of the process using the commercial software package Copra RF/FEA to generate a dataset with a high variability of equally distributed information. The relationship between the real fluctuating material yield strength and sheet thickness is correlated with roll load and final product shape quality. The acquired dataset is then used to develop a data-driven model for inline shape quality prediction.</p>