Abstract The static and dynamic mechanical properties of standard industrial robots differ strongly from common CNC-machines. For robot-based machining operations, these properties have to be considered. In this paper, a method for the optimal placement of the workpiece within the workspace, the design of the machining process and the compensation of toolpath deviations during the machining process of metallic workpieces is presented. The method is based on a coupled machine-process-model and the derivation of performance, accuracy and reliability indicators. The method was validated by the machining of aluminum workpieces and the evaluation of the accuracy improvement due to the multi-axis compensation mechanism.