During development of new vehicles, CAE driven optimizations are helpful in achieving the optimal designs. In body-on-frame vehicles, reducing weight of the frame without any down gage involves inducing cutouts or lightening holes with no effect on fatigue life. The cutouts are stress risers that by design are detrimental to fatigue life and ability to identify their locations that maintain the durability performance becomes more critical. This paper describes one of the methods used to reduce the weight of the vehicle without any down gage and still maintaining the durability performance for truck frame. In this method, load paths are being analyzed for each component and then the stress envelops are generated in fatigue code using complete proving ground loading events. A subsequent step includes tuning those cutouts to meet the durability strength and stiffness requirements. Automated process in resizing the lightening holes helps to reduce the cycle time for achieving the optimal cutouts. Final verification is carried out with the regular analysis procedure to make sure results are as expected.