Plug Gauge Manufacturing Process: Manufacturer's expalined along with Demo Video

Plug Gauge manufacturing process by Sawhney Engineering Company, an award-winning Plug Gauges Manufacturer in India 

Though ordinary looking, a plug gauge is one of the cheapest and most reliable inspection tool in the mechanical engineering world. There are several steps to make one simple looking plug gauge. We, being the top plug gauges manufacturer in India see it as our responsibility to educate the young aspirants the steps to take while engineering a simple looking go nogo plug gauge.

If you are still wondering what a plug gauge is? Check out this self-explanatory image below:

Coming on to the engineering part, there are a total of seven steps involved in the manufacturing process of a plug gauge.

1. Raw Material: Normally, the first step is to take a round metal bar and cut it to approximate lengths. The raw material is a appropriately shaped piece of metal which will be shaped according to choice of design.

2. Turning Process: This is the step where the basic shape of the plug gauge is formed. Here, a technician uses the grinder machine and grinds the corners to with both the go section and nogo section Once this part is complete, the unfinished product is moved onto the nulling machine where texture is created for better gripping and handling.

 3. Heat Treatment: Once, the dimensions have been checked and they are as per requirement. The plug gauge is sent for heat treatment process. This process takes anywhere from 6-24 hours and this ensures that the product is durable, long lasting and hard for repeated use. The heat treatment process helps the product retain its structural integrity.

4. Hardness Testing: There is only one way to find out if the heat treatment went well or not. It is hardness testing. Unlike, those dramatic TV series, we don’t file the gauge, we use the hardness tester to check the hardness limits of the plug gauge. Once, the hardness is found appropriate the plug gauge is sent for grinding process.

5. Grinding Process: The gauge is then sent to the grinder machine to grind off any dead metal sticking to the plug gauge after the heat treatment process. This is where we actually see the correct size and dimension, ready to use plug gauge.

6. Detailing: Having said that, the plug gauge is then sent for detailing. This is done via an engraving machine and the operator inputs the makers’ logo design along with the go nogo limits in engraving machine settings for the same to be engraved on the plug gauge.

7. Quality Check: The finished product is then sent to the quality department where a quality inspector checks the finish, specifications and detailing. With an approval from the quality team, plug gauge is then sent for packaging.


We hope that the information shared will help you and we also made a simple easy to understand video of the entire process. Check the video below to see the complete manufacturing process happening before you.

Sawhney Engineering Company is an award-winning precision component manufacturer in India. We are not just limited to precision components, our range extends to Gauges, Fixtures, CNC Machine Tool Holders, Shafts and Spindles.

In case you have any questions, feel free to contact us at +91-9810877174, 9810177174 and we will be happy to help you out with your issues.








Location: Plot No. 4, Punjab Oil Expeller compound, Meerut Road,, Ghaziabad, Uttar Pradesh 201003, India

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