During performing Computer assisted Total Knee surgery, surgeons have difficulties in orientation of cutting block before sawing procedure. The objectives of this study are develop design approach and fabrication of prototype, which able to eliminate stated difficulties. Thus, improve performance and cycle time of total knee surgery. Benchmarking with commercial product had been conducted, two designs of jig system were proposed. Selection of design was conducted using Pugh method. Two designs were compared based on specific requirements, in order to get the most acceptable design. Pugh method analysis shown that the second design give more advantages in handling, easy to operate, least cost in manufacture, and reduction of time in doing the total knee replacement than the first design. Prototype jig assembly consist of arm, base and cutting block were fabricated by rapid protyping for feasibility analysis. Then, simulation of fabrication by machining process was conducted through Mastercam Mill V8. All component were able to fabricated through machining. A prototype of jig system was fabricated using stainless steel typed SS316L, and evaluation of cutting procedure with saw bone confirmed that the second design is fulfill the objectives of this study.