Robust design is less sensitive to the manufacturing variation and its demand for controlling the manufacturing variation can be reduced. The existing robust design techniques are limited to solve individual synthesis problems, and these methods seldom consider the problem of tolerance sensitivity. This paper presents a method for tolerance sensitivity design and evaluation. First, tolerance sensitivity robustness is analyzed and the tolerance sensitivity robust design models are developed. Then, the matrix analysis method is introduced to evaluate complex assembly relationship among design functions and parameters. The results show that compared with origional mothod, the proposed method is siutble and reliable.