In the metal removal process industry, the current practice to optimise cutting parameters adoptsa conventional method. It is based on trial and error, in which the machine operator uses experience,coupled with handbook guidelines to determine optimal parametric values of choice. This method is notaccurate, is time-consuming and costly. Therefore, there is a need for a method that is scientific, costeffectiveand precise. Keeping this in mind, a different direction for process optimisation is taken byemploying the combined Taguchi method-simplex algorithm (TM-SA) for optimal parametric setting ofmanufacturing processes. The process parameters were optimised and the efficiency and robustness of themethod described in four literature cases. These cases involve high-speed flat-end milling, forming inhydrodynamic deep drawing, cup deep drawing and abrasive assisted drilling. The computations showedthat the TM-SA exhibited superior results in one of the cases and equivalent results in others. This impliesthat the proposed approach could comparably serve as an optimisation framework with significantadvantages of reducing experimental costs and allowing variable usages with the requirement of functionalderivation. It is also easy to use. The novelty of this article is the application of a distinctly new method inoptimisation for cost reduction and variable usages for the metal removal process. Potential applications ofthe proposed approach by material type is its usage in machining mild steel, grey cast iron, brass andaluminium with HSS and carbon steel, respectively, used as tools.