Thread Plug Gauge Automatic Measurement

Automate plug gauge inspection to boost quality control and production efficiency.

Thread Plug Gauge Automatic Measurement

A three-line gauge to measure plug gauges? There’s a Smarter Way.

S Company, a global leader in high-end bicycle components, ranks among the top private-label suppliers in the premium market. Their product lines include drivetrains, suspension systems, wheelsets, and electronic shifting systems.
With a dual structure of in-house production and supplier collaboration, S Company imposes strict requirements on internal thread dimensions and fit tolerances. Across both their own facilities and supply chain, thread plug gauges are widely used for incoming and in-process inspections to ensure assembly quality and on-time delivery.

Challenges

Difficulty in Quantifying and Tracing Thread Plug Gauge Wear

• Pitch diameter inspections of thread plug gauge still rely on traditional three-line gauges.
• Each measurement takes about 5 minutes per thread plug gauge.
• Heavy dependence on technician experience leads to inconsistent results.
• Difficult to quantify gauge wear, making quality control less reliable.
• Internal thread quality is compromised, risking downstream issues.
• Labor and plug gauge consumption increase, raising operational costs.

High Calibration and Dispute Costs

• Disputes over tap quality often require third-party plug gauge calibration.
• Calibration process takes 3–4 weeks, delaying production decisions.
• Lack of timely feedback raises production and quality risks.

Unclear Decision-Making

• Operators lack clear criteria for determining if a thread plug gauge should be reused or scrapped.
• This uncertainty leads to overuse, increasing the risk of inaccurate inspections.
• Premature disposal of gauges raises unnecessary replacement costs.

Solution

S Company deployed the USDV TIMI optical measurement system, enabling automated, high-precision inspection for plug and thread gauges.

Customer Feedback

“We upgraded plug gauges from simple pass/fail tools to quantifiable, predictive assets — now quality decisions are based on data, not guesswork.”~ Quality Manaager

Value Highlights

• Upgrade plug gauge inspection from manual judgment to AI-based automation.
• Significantly Reduce labor and third-party inspection costs.
• Implement digital gauge life-cycle management to prevent overuse or waste.
• Reduce third-party inspection costs and accelerate production decisions.
• Ensure thread quality through precise wear monitoring and earn customer trust.