During sheet metal forming operations, many different sources of non-controllable process variations usually display their effect, leading to a degree of uncertainty in the final parts’ quality. For this reason, statistical tools are increasingly used in combination with FEM numerical simulation. The focus is moving in recent times beyond mere feasibility to robustness of the product and process being engineered. Ensuring robustness is the next big challenge for the virtual tryout / simulation technology. In this paper, some of the numerous applications of statistical analysis combined with simulation of sheet forming processes are presented and discussed: 1) sensitivity analysis under uncertainty, 2) process capability studies, 3) reliability assessment, 4) reliability optimization, 5) process design optimization under uncertainty. Problems of type 2) and 5) will be particularly addressed, by giving the description of some innovative methods and applications.