Hazardous potential in industrial environments is normally assessed by means of immission-based sampling and analyses. This approach is not adequate, if effects of specific technical adjustments at machine tools or working processes on hygienic parameters should be assessed. This work has focused on the optimization of a manufacturing process (electrical discharge machining, EDM), with regard to risk reduction assessment. It is based on emission analyses rather than immision analyses. Several technical EDM parameters have been examined for their influence on air-based emissions. Worktools and workpieces used have a strong influence on aliphatic compounds and metals but not on volatile organic compounds (benzene, toluene, ethylene-benzene and xylene (BTEX)) and polycyclic aromatic hydrocarbons (PAHs) in air emissions. Increasing the dielectric (mineral oil) level above processing location decreases BTEX, chromium, nickel and PAH emissions. Aliphatic compounds, in contrast, increase in air emissions. EDM current used has a positive relationship with all substances analyzed in air emissions. Indicative immission concentrations, as can be expected under EDM conditions, are estimated in a predictive scenario. The results of this characterization give rise to an important conclusion in that risk assessment so far has been using incorrect parameters: total aliphatic compounds. Maximum level of chromium is reached long before limit values of aliphatic compounds are exceeded. Because of the fact that metals, like chromium, also have a higher hazardous potential, metal analysis should be introduced in future risk assessment. This experimental approach, that captures total emission of the electrical discharge machine, and is not solely based on immission values, has lead to a better understanding of the production process. This information is used to extract recommendations regarding monitoring aspects and protection measures.