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The search for improvements in fuel economy, specific power, exhaust emissions and refinement leads to an increasing number of experimental variables and flexibility in their operating strategy. This makes identification of optimum settings and robust solutions more demanding. New test and analysis techniques are required to identify underlying trends and sensitivities in order to determine, with some confidence, the technical and commercial benefits of changes to one or more parameters. Greater emphasis on experimental design will therefore be essential for any engine research and development programme. Design of experiments (DoE) techniques have been widely used for identifying optimum settings. Traditional experimental designs can be improved by including engineering knowledge more directly into the design process and by providing information on a continuous basis during the test programme.