The 81mm mortar barrel is a precision component requiring exact internal diameter measurements, which poses challenges in both machining and inspection using conventional equipment. This study addresses issues related to measurement variability and reprocessing due to inconsistencies in bore measurements along different barrel positions. Using Gage R&R analysis, we identified the limitations of the existing measurement system, particularly its inability to provide consistent and detailed readings along the full barrel length. To resolve these challenges, a revised measuring system was developed and compared with the existing system, showing enhanced accuracy and reduced errors. The improved system was subsequently applied to the barrel machining process, resulting in quality improvements in the final product.