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The uncertainty of the engineering system increases with the growing complexity of the engineering system; therefore, the tolerance to the uncertainty is essential. In the design phase, the output performance should reach the design criterion, even under large variations of design parameters. The tolerance to design parameter variations may be measured by the size of a solution space in which the output performance is guaranteed to deliver the required performance. In order to decouple dimensions, a maximum solution hyperbox, expressed by intervals with respect to each design parameter, is sought. The proposed approach combines the metaheuristic algorithm with the DIRECT algorithm where the former is used to seek the maximum size of hyperbox, and the latter is used as a checking technique that guarantees the obtained hyperbox is indeed a solution hyperbox. There are three advantages of the proposed approach. First, it is a global search and has a considerable high possibility to produce the globally maximum solution hyperbox. Second, it can be used for both analytically known and black-box performance functions. Third, it guarantees that any point selected within the obtained hyperbox satisfies the performance criterion as long as the performance function is continuous. Furthermore, the proposed approach is illustrated by numerical examples and real examples of complex systems. Results show that the proposed approach outperforms the GHZ and CES-IA methods in the literature.