Wire EDM machines have become an integral part in the metal removal industry for more than 30 years. Once found primarily in Tool & Die shops, new industries have acquired EDM machines and implemented them into medical, aerospace, and energy manufacturing processes. Since their invention, wire EDM machines have seen significant increases in cutting speeds and technology. They now run unattended with the addition of a automatic-threader and robots. Wire EDM machines are now an key part of manufacturing. Increased demand and usage of equipment often results in neglect of the simplest requirements of operation, preventative maintenance (PM). Without strict PM discipline, problems arise, and blame is associated with the consumable.