The present study was intended to suggest a process of physical user interface (PUI) design guideline development, which was validated with mobile phones. The process consisted of five stages including component and dimension analysis, function and environment analysis, evaluation criterion generation, literature review, and design guideline development. The process was applied to develop 19 mobile phone PUI design guidelines by identifying 28 components, 9 dimensions, 51 functions, 7 environmental conditions, and 15 criteria. The systematic approach of the process would be useful for manufacturers to develop design guidelines in an efficient manner.