Metals, Steel, Aluminum & Coil Processing worked example

Gauge Variation with highest gauge reading of 0.03 in: a worked example

This worked example runs the gauge variation numbers for a tougher week than the baseline: highest gauge reading of 0.03 in instead of the typical 0.06 in. Check gauge variation across a coil or lot by entering the highest and lowest thickness readings and the nominal gauge target, then see the spread and how the midpoint sits versus nominal.

The inputs for this scenario

  • Highest gauge reading: 0.03 in (the input this scenario stresses; the baseline uses 0.06)
  • Lowest gauge reading: 0.06 in (held at the documented default)
  • Nominal gauge target: 0.06 in (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gauge range = highest gauge reading - lowest gauge reading.
  • Gauge spread works out to 47.5 % at these inputs, and this is the headline figure for the scenario.
  • Spread works out to 0.03 value at these inputs.
  • Minimum works out to 0.03 value at these inputs.
  • Maximum works out to 0.06 value at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where highest gauge reading sits at 0.06 in and the headline result is 0 %, this scenario lands almost exactly on the baseline at 47.5 %.
  • Use it at incoming inspection, during a coil run, or when investigating downstream defects that point to thickness inconsistency. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Gauge spread: 47.5 % (headline result)
  • Spread: 0.03 value
  • Minimum: 0.03 value
  • Maximum: 0.06 value

Run it with your numbers

  • To rerun this with your own numbers, open the live Gauge Variation calculator, set highest gauge reading to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.