Biaxially oriented polypropylene (BOPP) films are used in a variety of areas around the world. They are especially suited for food packaging and industrial usages due to their high productivity. Many studies on stretchability regarding crystal structure changes have been reported by various researchers, since the machine speed has been increasing and the demand to produce thinner films has been becoming more important.Furthermore, a number of studies on the surface structure of BOPP films with crater-like roughness have been reported since the 1980's. Although the crater-like surface roughness was formed under specific film process conditions, the formation mechanism and the controlling method of the crater-like film surface are yet to be clarified. In this report, the authors demonstrate a new hypothesis as to the crater-like film surface roughness formation mechanism by analyzing the morphology of the surface layer of polypropylene (PP) sheets and by investigating the relationship between the surface structure changes and the entire structure changes. As a result, it was found that it needs to have over critical crystallization time in order to form the crater on the surface of BOPP film, and the crater formation mechanism was closely related not only to the surface structure changes but also to the deforming phenomenon of spherulite in PP sheet during stretching. Furthermore, this report will show the controlling factors in the formation of the crater structure from the view point of production conditions.