Tool, Fixture & Gauge Maintenance Procedure in Manufacturing

Tools, fixture & gauges are critical assets in any manufacturing organization. Their condition directly affects product quality, dimensional accuracy, productivity, and customer satisfaction. Poor maintenance can lead to defects, rework, downtime, safety risks, and audit non-conformities.

This article provides a complete, practical, and ISO/IATF-aligned procedure for tool, fixture, and gauge maintenance, including preventive maintenance planning, responsibilities, records, and best practices used in automotive and engineering industries.

Purpose

To establish a systematic method for maintaining tools, jigs, fixtures, and gauges to ensure consistent product quality, equipment reliability, and compliance with ISO 9001 and IATF 16949 requirements.

Scope

This procedure applies to all production tools, jigs, fixtures, templates, gauges, and inspection devices used in manufacturing, assembly, and quality control processes.

Definitions

Tool: Cutting or forming device used in production (drills, dies, punches, inserts, etc.)

Jig: Device that holds and guides the cutting tool.

Fixture: Device that securely holds the workpiece during machining or assembly.

Gauge: Instrument used for checking dimensions (plug gauge, snap gauge, height gauge, etc.)

Preventive Maintenance (PM): Planned maintenance activities performed at scheduled intervals to prevent failure.

Responsibility

Production Operator

• Daily cleaning and visual inspection
• Proper handling and storage
• Reporting abnormalities

Maintenance Department

• Scheduled preventive maintenance
• Repair and replacement
• Spare management

Quality Department

• Calibration control of gauges
• Verification of measurement accuracy
• Maintenance record review

Production Supervisor

• Ensuring compliance on shop floor
• Monitoring maintenance schedules

Importance of Maintenance in Manufacturing

Proper maintenance of tooling and gauges ensures:

• Consistent product quality
• Reduced rejection and rework
• Improved machine utilization
• Longer tool life
• Reduced production downtime
• Safety improvement
• Compliance with ISO 9001 & IATF 16949
• Customer satisfaction

Poorly maintained fixtures or gauges can cause dimensional variation even when machines are perfectly set.

Tool Maintenance Procedure

Daily Activities (Operator Level)

• Clean tools after use
• Remove chips, dust, coolant residue
• Apply rust preventive oil where required
• Check for wear, chipping, cracks, or deformation
• Ensure proper storage in designated locations

Weekly Inspection

• Check alignment and mounting condition
• Verify clamping effectiveness
• Inspect cutting edges or functional surfaces
• Check lubrication condition
• Tighten loose fasteners

Monthly Preventive Maintenance

• Detailed inspection of tool condition
• Replacement of worn components
• Regrinding or reconditioning if applicable
• Verification of dimensional accuracy
• Updating maintenance records

Jig & Fixture Maintenance Procedure

Jigs and fixtures require high precision because they directly control part positioning.

Cleaning and Protection

• Remove metal chips and burrs
• Clean locating pins and surfaces
• Protect from corrosion
• Ensure no foreign particles affect seating

Functional Checks

• Inspect locating elements for wear
• Verify clamping force and mechanism operation
• Check hydraulic/pneumatic lines if used
• Confirm repeatability and positioning accuracy

Structural Inspection

• Check for cracks or deformation
• Verify weld integrity
• Inspect base plate flatness
• Confirm mounting bolts condition

Alignment Verification

Misalignment can cause major dimensional defects.

• Check datum references
• Verify perpendicularity and parallelism
• Conduct trial run with master component

Gauge Maintenance & Control Procedure

Gauges ensure product conformity; therefore, their maintenance is critical.

Handling Requirements

• Store in protective cases
• Avoid dropping or impact
• Use only for intended purpose
• Maintain cleanliness

Routine Checks

• Visual inspection for damage or wear
• Clean measuring surfaces
• Verify smooth movement (for snap gauges, bore gauges)
• Ensure identification marking is readable

Calibration Control

• Calibrate as per defined schedule
• Maintain calibration status labels
• Remove expired gauges from production
• Keep calibration certificates

Calibration Procedure for Instruments

Intermediate Verification

Between calibrations, verify gauges using master standards to ensure accuracy.

Preventive Maintenance Checklist

Storage & Identification Control

Proper storage prevents accidental damage and mix-ups.

• Use designated storage racks or cabinets
• Maintain tool identification numbers
• Segregate OK, Under Maintenance, and Rejected tools
• Control issue and return through registers
• Protect precision surfaces

Handling of Damaged Tools and Gauges

• Immediately remove from production
• Tag as “UNDER MAINTENANCE” or “UNDER REPAIR”
• Inform supervisor/quality department
• Repair or replace before reuse
• Record corrective action

Documentation & Records

Maintain the following records:

• Tool inventory list
• Preventive maintenance schedule
• Maintenance checklists
• Calibration records
• Repair history
• Tool life data (if applicable)

Proper documentation supports audits and continuous improvement.

Link with ISO 9001 & IATF 16949 Requirements

This procedure supports compliance with:

ISO 9001

• Clause 7.1.3 Infrastructure
• Clause 7.1.5 Monitoring and Measuring Resources
• Clause 8.5 Production and Service Provision

IATF 16949

• Tooling management requirements
• Preventive maintenance expectations
• Measurement system control

Auditors frequently verify tooling maintenance as part of process audits.

Benefits of an Effective Maintenance System

• Stable production processes
• Reduced variation
• Lower scrap and rework
• Increased productivity
• Extended tool life
• Improved delivery performance
• Higher customer confidence
• Better audit results

Best Practices from Industry

• Implement tool history cards
• Use color coding for calibration status
• Digitize maintenance records
• Train operators in basic maintenance
• Use TPM (Total Productive Maintenance) principles
• Monitor tool life trends
• Conduct periodic audits of tooling

Procedure:

Infrastructure and availability of Resources:

• Prepare a master list of Tools, Gauges and Fixtures.
• Tool, Gauge and Fixture locations should be mentioned in the List.
• The list should be updated at every three months for any deletion /addition.

Identification and Traceability of Tool, Fixture & Gauge:

• All tools, Gauges and Fixtures should have a Unique identification number for easy traceability on the shop floor any of as a Model and operation number.
• Ensure identification is marked on every Tool, Gauge and Fixture.

Preventive Maintenance of Tool, Fixture & Gauge:

• To ensure that the Tool, Gauge and Fixture preventive maintenance schedule is prepared.
• To ensure that preventive maintenance parameters are defined for all the Tools, Gauges and Fixtures.
• To ensure preventive maintenance is done as per the schedule defined based on the number of stock/production.
• If any problem is found during the preventive maintenance, the Tool, Gauge and Fixture should be repaired in-house if possible or immediately call to the external agency without any delay and duly inform to Tool Maintenance Head.
• If not repaired, please put a tag under maintenance.
• The work carried out is recorded in the prescribed format.

You may like to know about the Machine maintenance procedure

Breakdown Maintenance of Tool, Fixture & Gauge:

• A Verbal Intimation and Breakdown Slip is made from the respective department to the Tool Maintenance Technician regarding the breakdown of the Tool, Gauge and Fixture
• The Tool Maintenance Shift Technician will immediately go and assess the problem. At this time, he will organize manpower to attend to the problem on a priority basis. He will communicate the expected time of completion of work. Also if more than one breakdown is to be attended then priority is taken from HOD Maintenance in consultation with the concerned departments
• Once work is done, the trial is conducted and the Breakdown Maintenance of Tool, Gauge and Fixture are to Production after successful running. If some temporary arrangement is made to run the Breakdown Maintenance of the Tool, Gauge and Fixture at this particular point of time due to production requirements or other reasons, then the same is communicated to the Production and Quality In charge.
• If the problem is not rectified in-house, immediately call the external agency without any delay and duly inform to Tool Maintenance Head.
• The work carried out is recorded in the prescribed format.

Breakdown Analysis:

• Breakdown analysis will be done for the top 1 breakdown & in case of repetitive (more than 3 times) & more than 2 hours.
• Effectiveness monitoring for 3 months for the countermeasure action taken.
• Horizontal deployment (if applicable) is also to be ensured for the corrective action & preventive action taken against the breakdown.

Spare Parts Procurement and Inventory:

• A record is maintained for tool spare inventory, consumption, Lead time and procurement.

Conclusion

A well-defined tool, fixture, and gauge maintenance procedure is essential for maintaining product quality and operational efficiency in manufacturing. Preventive maintenance, proper handling, regular inspection, and calibration control help prevent unexpected failures and ensure consistent performance.

Organizations that implement structured maintenance systems experience fewer defects, less downtime, improved productivity, and stronger compliance with quality management standards.

Frequently Asked Questions (FAQs)

What is tool maintenance in manufacturing?
Tool maintenance is the systematic cleaning, inspection, repair, and replacement of production tools to ensure reliable performance and product quality.

How often should fixtures be maintained?
Basic cleaning should be done daily, inspections weekly, and preventive maintenance monthly or based on usage.

Why is gauge maintenance important?
Inaccurate gauges lead to incorrect acceptance or rejection of parts, directly affecting product quality and customer satisfaction.

What is the difference between maintenance and calibration?
Maintenance ensures the physical condition and functionality of equipment, while calibration verifies measurement accuracy against standards.