Abstract The paper deals with a study on technologies to enhance the manufacturing productivity of a product consisting of sculptured surfaces. A process planning system coupled with real time machining is proposed such that the productive machining plan and tool motion can automatically be generated once available resources and machining know-how are given for the metal cutting-EDM mixed environment. The system proposed consists of geometry feature recognition, cutting mode and tool selection, real time tool path generation with adaptive feedrate generation using concurrent real time machining simulation. The system was prototyped to verify the feasibility. Successful results were obtained.