Abstract: To solve the problem of deformation of the cigar group pusher in REX-Ⅱ-S cigar packer, the pusher was optimized through finite element analysis. The results of mechanical analysis indicated that the maximum pressure on the pusher was 0.023 522 7 MPa. The simulation with ABAQUS finite element software showed that the maximum stress and the maximum deformation of the pusher were 53.63 MPa and 2.789 mm respectively. Five key dimensional parameters of the pusher were optimized with orthogonal test and integrated balance method, the optimized mass of the pusher increased by 4.03%, the maximum stress and the maximum deformation decreased by 48.09% and 44.07% respectively. The new pushers were tested on two REX-Ⅱ-S cigar packers in Jinan Cigarette Factory, the results showed that the average working life of the pusher prolonged by 125.97% and 133.33% separately. This technology provides a support for promoting the performance of cigar packer.