"The progress on FEM numerical simulation tools can increase the level of predictability and precision,but these tools remain dependent on the quality of experimental data defining the model parameters of materials and the process. Unfortunately, these experimental data always has inherent variabilities regarding process parameters, material properties and the sheet's dimensional variations. As a consequence, there are always discrepancies between results from physical tests and numerical simulation trials. Moreover, the sensitivity of finite element models of sheet metal forming simulation is not always sufficient to take into account the very small variations of input parameters. To answer these challenges, in this paper a novel approach to determine the minimum sensitivity threshold in numerical simulation of the sheet metal forming process is proposed. This method contributes importantly to the computer experiments when using Design of Experiments in executing uncertainty propagation. Moreover, the influence of process parameters on springback in sheet metal forming is predicted by sensitivity analysis."