Understanding the effect of input variation on output performance via tolerancing has been traditionally been done via ‘worst case’ or statistical (RSS) approaches. Now that Monte Carlo Analysis can be performed via Minitab, we showcase the use of this powerful and flexible tool. We also turn to the progression from the critical to design measures (CTDs) and the processes that will create them and their critical to process measures (CTPs).  Finally, we look at effective piloting of new processes as part of process development.