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In the mould making process, inevitable human error can arise with the authentication, verification, measurement, recording, programming and arrangement of electrodes prior to the electro-discharge machining (EDM) process. The focus of research is to develop effective methodologies that can proactively eliminate preventable errors. Cost-effective multi-sensor fusion techniques for the identification of electrodes; verification of the sequence and the precedence between the finishing, roughing and texturing tools used were developed and implemented in one of the largest mould-maker in Asia. This implementation in turn has further improved the performance of the EDM process, particularly in the manufacturing of large, fast turn around, high value engineered moulds. In addition, a verification and diagnostics engine to verify the identity and sequence of the electrodes placed on the automatic tool change (ATC) prior to the actual spark erosion process was developed. With the implementation of the prototype, Fu Yu Corp Ltd has reported that it is now possible for two operators to manage five EDM machines concurrently (instead of 3 machines), representing a direct benefit gain of 66%.