In a sheet metal forming process, fracture and wrinkle are the most difficult task in new parts launching. The variation in process condition generates the fracture and wrinkle fluctuation. The fracture and wrinkle are very sensitive to the process conditions, then the main effects of the design variables cannot be obtained from the standard mean analysis. Therefore, in order to minimize the fracture and wrinkle in parts of automobile, a special method to counterpart is required. In this study, a new design method to achieve the optimal in the sheet metal forming process is proposed. The effectiveness of the proposed methods is shown with an example of the parts of fracture and wrinkle.