Abstract: A method for developing testing configurations and a computer system operable to implement the same. The method includes the steps of identifying factors to be tested and levels for each factor; selecting a Hadamard matrix of an appropriate size such that for any integer 1, 2 . . . n, the Hadamard matrix has a size 2n and at least (2n−1) columns, and maintains orthogonality of at least strength n when columns are selected sequentially; and creating a configuration matrix from the selected Hadamard matrix. The configuration matrix is created by first creating an integer matrix from the Hadamard matrix by combining columns of the Hadamard matrix where necessary, and replacing unassigned variables in the integer matrix in a manner that improves coverages. In one embodiment, a frequency matrix and a proportionality matrix are used to improve coverage when replacing unassigned variables.