Sheet metal parts are widely used in the assembly of aircraft. The most common method of joining sheet metal parts is through riveting. There are many parameters associated with a riveting process that affect the quality of rivets and the integrity of the final assembled product. This paper presents a study on the effect of some controllable process parameters in riveting (i.e., the sequence of riveting, distance between rivets (pitch), and gap between sheets) on the quality of riveted lap joints and the formed rivets. The study is performed on a one eight-inch nominal diameter flat head Tinner rivet and 0.064-in.-thick aluminum sheet. Finite element simulation is used as a means of modeling and analysis of the riveting process. Statistical design of experiment is employed to analyze the simulation data. A good combination of riveting process parameters is found which minimizes the residual stress in sheets and rivets, bulging and material growth in sheets, and which reduces the chances of postriveting clearance in a riveted lap joint.