Design of experiments (DOE) has been applied to evaluation of alternative slug riveting methods. The PDCA cycle was applied to process optimization. Brainstorming identified the problem, evaluated existing knowledge and established a set of experiments. L8 full and fractional factorial experiments were per formed with the results being analyzed using ANOVA statistical analysis, Taguchi Signal-to-Noise analysis and engineering common sense. The outcome was verification of robust processes and a fuller understanding of what controllable factors influence this robustness.