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A connecting rod of IC engine is subjected to complex dynamic loading conditions. Therefore it is a critical machine element which attracts researchers’ attention. This paper aims at development of simple 3D model, finite element analyses and the optimization by intuition of the connecting rod for robust design. In this study the detailed load analysis under in-service loading conditions was performed for a typical connecting rod. The CAD model was prepared taking the detailed dimensions from a standard machine drawing text book. Based on the gas pressure variation in the cylinder of an IC engine, the piston forces were calculated for critical positions. MATLAB codes were written for this calculation. Altair Hypermesh and Hyperview were used for pre-processing and post-processing of the model respectively. The finite element analyses were performed using Altair Radioss. The results obtained were compared to a case study for the field failure of the connecting rod. By comparing the induced stress result with the yield strength of the material, the component was redesigned. This was done to save some mass keeping in mind that the induced stress value should be well below the yield strength of the material. The optimized connecting rod is 11.3% lighter than the original design.