A laser‐ultrasonic system has been installed on a seamless tubing production line of The Timken Company and is being used to measure on‐line the wall thickness of tubes during processing. The seamless process consists essentially in forcing a mandrel through a hot cylindrical billet in rotation and typically results in fairly large wall thickness variations that should be minimized and controlled to respect specifications. The system includes a Q‐switched Nd‐YAG laser for generation of ultrasound by ablation, a long pulse very stable Nd‐YAG laser for detection coupled to a confocal Fabry‐Perot interferometer, a pyrometer to measure tube temperature and two laser Doppler velocimeters to measure the coordinates of the probing location at the tube surface. The laser, data acquisition and processing units are housed in a cabin off line and connected to a front coupling head located over the passing tube by optical fibers. The system has been integrated into the plant computer network and provides in real time thickness data to the plant operators. It allow much faster mill setups, has been used since its deployment for inspecting more than 100,000 tubes and has demonstrated very significant savings. © 2003 American Institute of Physics