New advances in finite element method based process modeling system, DEFORM includes optimization techniques, sensitivity analysis and probabilistic modeling.  The sensitivity and probabilistic modeling framework in DEFORM will enable the user to systematically analyze the variabilities and uncertainties associated with the processing conditions, boundary conditions, material properties on the desired process outcomes such as distortion, residual stresses, microstructure evolution and mechanical property response.  This infrastructure in DEFORM enables the user to analyze thermo-mechanical and metallurgical responses of the components during forging, heat treatment and subsequent machining operations.   This presentation will specifically focus on heat treatment modeling capabilities with in DEFORM system.  Few case studies that highlight wide ranging process modeling applications will be presented.