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The webs such as paper, plastic film and thin metal are produced by Roll-to Roll manufacturing system, and are wound into a roll in the final process of this system. However, if the winding conditions of the web are inappropriate, the defects such as gage band, wrinkle and slippage will occur in wound roll, and then quality of products is significantly reduced. In previous studies, some analysis models of in-roll stress considering various factors, have been established to predict the defects. However, as far as authors know, there is few research regarding the gage band. In particular, the plastic films used for high functional flexible devices are being thinner, the defects can occur easily. In this paper, the in-roll stress analysis considering the web thickness variation in width direction and compressive deformation of web in the radial direction using the Hertz contact theory is presented. Moreover, optimization of winding conditions is conducted to prevent simultaneously the gage band, wrinkle and slippage. As a result, it was confirmed that the presented analysis can estimate the radial stress distribution of wound roll in the width direction. And, the effectiveness of optimized wind-up tension is verified theoretically and experimentally.