This paper presents an attempt to develop an approach to predict the optimal process parameters for the Hole punching process on sheet metal. The Taguchi method is used to define the experimental procedure by its orthogonal array. The multiple responses of the Hole punching process, hole diameter and hole offset are optimised by the Grey Relational Analysis procedure. The statistical analysis of variance reveals the significant parameters which affect the process by analyzing the input parameters with the grey relational grade. The Non linear model obtained by this analysis is further processed by a Meta heuristic algorithm to obtain the optimality.