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Mechanical component design by safety factors using nominal values without considering uncertainties may lead to designs that are unsafe, or too conservative and thus not efficient. Design of a helical compression spring is one of complex and time consuming design procedure. This paper presents development of mathematical models to predict the outer diameter of a typical helical spring. This paper presents unique method to investigate engineering problem, its analysis, mathematical modeling and optimization with the help of RSM-response surface methodology and design of experiments (DOE). Response surface methodology, which is a statistical approach of design of experiments, is being applied with combined probabilistic design to optimize the design responses in the case of simultaneous variations of its design parameters. The technique is proved to be efficient and general purpose modeling a variety of components.