The purpose of this study is to investigate the reason for the failure of the back plate in the wet grinder manufacturing company and to improve the design for getting a quality product. In general, experimental studies tend to be time-consuming and expensive for failure analysis. So, numerical methods such as finite element modelling (FEM), is used for investigating the cause of failure. In spite of the fact that finite element analysis has been frequently used as a means of investigating the design failure, small empirical evidence exists in the literature that it is used in the wet grinder manufacturing industries. Systematic analysis of the failure enables the wet grinder manufacturing organizations to eliminate or reduce the failure and to survive in the competitive environment. For this purpose, finite element analysis is conducted on a three-dimensional model to investigate the reason for real-time failure. The simulated model is validated against the failed product. In addition to the finite element analysis, regression analysis and response optimisation are performed to examine the effects of the parameters such as the rib thickness, positioning of bearing stem and backplate material on the critical load and weight of the backplate. A regression equation is formed to select the optimum parameters so that the von-mises stress and deflection are less. The optimum parameters were modelled and analysed to verify the results obtained in the response optimization. Finally, an optimized design is proposed with suitable material and design modifications to overcome the failure of the back plate