Parametric sensitivity analysis is being implemented in DEFORM to model variabilities in processing conditions, material data and boundary conditions that are typically encountered during manufacturing processes.  Probabilistic modeling techniques are being implemented in DEFORM for modeling the evolution of residual stresses and microstructure so that the uncertainties associated with processing conditions and incoming starting grain size distribution can be effectively analyzed. The proposed DEFORM simulation infrastructure will enable multiple operations (Forging, Heat Treatment, Machining and Spin/Service models) and multiple run (DOE runs) environment.  The objective is to perform selected sensitivity and probabilistic analysis wherein more useful, robust and better modeling results can be obtained without paying a penalty for computation time.  This presentation will highlight the sensitivity and probabilistic modeling capabilities of DEFORM system.