Cement manufacturing process is not stable and efficient due to the bulk nature of the crawler chain system. The bulk nature of the crawler chain during operation uses high energy that is also a major concern during operation. For decades now, researchers have used several approaches to optimize the design of crawler chain system to improve stability, efficiency and energy during cement manufacturing. The weight of the crawler chain design is still heavy with several operational problems being reported during cement manufacturing. It is therefore imperative to optimise the current design of crawler chain system such that the system operates with speed at optimal weight, which will not lead to mechanical failures. As such optimal weight and at low operational cost and low operational energy will be achieve during operation. In the current study, the tool of finite element analysis is used to optimise the weight of the crawler chain design during operation. The effects of material used and their impact on weight is modelled theoretically and validated by finite element analysis. The following facts were revealed after theoretical model and finite element analysis (1) it showed there was an optimal weight that gave optimal performance during cement manufacturing process. (2) It also revealed that to improve on performance and speed, the weight of the crawler design must be minimised. It was however revealed that there is a close correlation between theoretical model results and results of finite element analysis.