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Vacuum carburizing is carried out on Aero engine gears to obtain high case depths of the gear teeth to resist wear and tear. The depth of carburizing has to be uniform and consistent to achieve long life of the aero engine gears. The case depth is sensitive to a lot of parameters involved in the process of case carburizing. It is necessary to first identify the significant factors and then optimize it through repetitive iterations. Design of Experiments has been utilized to identify critical to quality parameters and evolutionary optimization techniques have been used to fine tune their values.Vacuum carburizing is carried out on Aero engine gears to obtain high case depths of the gear teeth to resist wear and tear. The depth of carburizing has to be uniform and consistent to achieve long life of the aero engine gears. The case depth is sensitive to a lot of parameters involved in the process of case carburizing. It is necessary to first identify the significant factors and then optimize it through repetitive iterations. Design of Experiments has been utilized to identify critical to quality parameters and evolutionary optimization techniques have been used to fine tune their values.