The numerical simulation of the forming process is a consolidated technique to verify, a priori, the effectiveness of the designed “method” to realize components obtained by sheet metal forming. As it is used in the industrial field at present, the limit of the forming simulation is that simulation results are based on an initial hypothesis that isn’t really true, that is on the hypothesis that the forming process is deterministic. Facts prove such affirmation is wrong considering that each input variable/datum of the simulation is non-deterministic by definition [1]. Therefore, a more realistic approach that uses the process simulation should consider this uncertainty by treating the process parameters as uncertain in an admissible domain. The authors are, at the moment, engaged in the development of an on line control and test system based on acquisition modules composed by a laser and two CCD video cameras. Its aim is to allow the statistical monitoring of the forming process through the investigation of the produced parts, and to point out, with a sufficient confidence level, situations of incipient process drift. The sampling frequency is 1, 2 parts per minute depending on the part main dimensions, therefore an express loading system of the part has been designed without clamps adoption [2]. The support provided by the non-deterministic simulation to the on line control system is very important. In fact, in the first phase of the production screening, for each produced part it allows to verify the areas that have a higher “risk” of defect on the basis of the simulation results. Moreover, as well as the simulation supplies useful suggestions on the areas of each piece at top priority where the quality control is executed, the quality control system can also provide interesting information for the non-deterministic process simulation system, thanks to the data and the measurements carried out on line, in order to increase the numerical-experimental correlation of the designed control system.

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