There is an increasing demand for high quality metal stamped parts. In general, burr formation is the main defect found subsequent to the blanking process. This defect must be strictly removed specifically for consumer products in order to prevent any kind of injury to the operators. Such a removal process results in an increase of the production cost. The unique merit of the counter-blanking process focuses on fabricating the burr-free blanked parts. However, it is difficult to control the numerous process parameters involved in this process in order to achieve the burr-free blanked parts. Thus, this study aims at investigating the process parameter design for the counter-blanking process by means of combining the finite element method (FEM) and statistical analysis techniques, including the Taguchi method and the analysis of variance (ANOVA) techniques. The results indicate that the process parameter of blanking clearance has a major influence on the die-roll formation features of the burr-free blanked part, respectively followed by the punch penetration depth and the same level of influence of the two process parameters of punch and die diameters in the second step. To conclude, this technique could be applied as a tool to achieve good quality of the burr-free blanked parts by optimizing the value of the process parameters and their favorable combinations.