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During the design stage, certification testing, or in field problem solving, t is of value for engine designers and engineers to have an understanding of how robust the engine design is to variation in the manufacturing process, in-use wear, controller and the testing processes. In this paper, a sensitivity analysis is performed on a parametric GTpower diesel engine model and using Robust Design methods NOx defects are reduced. Sensitivity analysis is conducted using a Plackett-Burman DOE. The DOE is performed on a 6 cylinder, direct-injection, turbocharged diesel engine model in GTpower, while Minitab is used for the experimental design and the factorial sensitivity analysis. It was found that the NOx population distribution was unacceptably high, yielding a 7.4% defect rate relative to an upper control limit of 5 (g/kw-hr).