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Recent developments in diesel engine technologies have led to considerable emissions and performance improvements, however the task to calibrate the increased degrees of freedom is challenging and complex. There is a requirement for improved experimental and data processing approaches that simplify and accelerate the calibration procedure. This paper presents an approach that simplifies the analysis of a six factor experimental system, where the settings for a multiple injection strategy, exhaust gas recirculation and boost pressure have all been investigated. Design of Experiments (DoE) and optimization techniques have been integrated and applied at five speed and torque conditions, in order to define calibration changes that meet various constraint criteria. The calibration changes determined at these sites have been extrapolated over the region of the operating map covered in the New European Drive Cycle.