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Manufacturing processes play a major role not only in the attainment of high product quality, but also in the reduction of manufacturing and consequently also product costs. In manufacturing industries tools used are of major importance in this respect, as it is very expensive and critical in the process since it is tool dominant process and their job to convert products or components. In mass productions, wear and chipping of tools is inevitable. Hence reconditioning of tools play vital role since it is not possible to discard the tools for minor damages or flaw, as the tool cost is very high and expensive. However there are variables to consider geometry, material, defect and coating all play a part in driving the decision to recondition a tool. The processes generally used for reconditioning of tools are welding overlays, grinding, machining and using it for next applicable size etc.