Thanks for all the info, but perhaps I need to clarify.
1) I want to perform a process validation; after I already have picked the appropriate/optimal operating conditions. In order for me to complete the process validation I need to run the process at each extreme (allowable tolerances) of the various conditions. This will demonstrate that we have picked the correct settings and allowable ranges. So basically I have used jmp to find the optimized design, and I now I want to use jmp to tell me how to check the model.
2) At the end of my process, I just really care about 2 parameters Pass/fail Both answer does the product function as intended or not. So I guess it would be a categorical response. Additionally the test would be destructive. So how many samples do I need?