The development of new vehicles often goes through a long process. Simultaneous engineering could integrate process and development of products in parallel. The front rail is one of the important components of the body frame. According to the recent studies, this paper proposes the structural design process of the front rail by using the basic theory of simultaneous engineering. Then the stamping process analysis of the front rail is carried out, and the structure optimization and cost analysis are completed. Hence, the CAD model of the part is perfected at the part design stage, so as to reduce the development cost, shorten the development time and improve the quality of design.