The present work investigates the effect of process parameters like powder concentration (Cp), peak current (Ip), pulse on time (Ton), duty cycle (DC) and gap voltage (Vg) on MRR, Surface Roughness (SR), Recast Layer Thickness(RLT) and micro-hardness(HVN) simultaneously during PMEDM of H-11 die steel. Taguchi’s L27 orthogonal array was used to carry out the experiments with silicon carbide (SiC) powder suspended to the dielectric fluid using copper as tool electrode. Multi-objective optimization using Grey Relational Analysis was used to determine the optimal setting of process parameters for maximum MRR, minimum SR, RLT and maximum HVN simultaneously. The effect of each process parameter was studied and the optimal parametric setting was established using Taguchi technique. The results were verified by conducting confirmatory tests. Microstructure analysis was carried out on the machined surface obtained from the optimal set using Scanning Electron Microscope (SEM) to investigate the surface modification on the die steel. GRA exhibits an improvement of 0.1055 in the Grey Relational Grade.The tendency of deviation of the response curves suggest that “the third level of parameters for powder concentration, first level of Ip, second level of Ton, third level of DC and second level of Vg” offer maximum GRG when machined using PMEDM.