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What does "Ok then" mean? Can one use this in his or her conversation? Will this offends the hearer? I just used this while mailing my boss. Will that be ok?
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In broad terms, it mans that you agree because of some reason that has been given.

It's not inherently offensive, but only say it if you have a friendly and very casual relationship with your boss.

emailing, not mailing.
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Dear Clive, thank you very much for your kind reply and for your correction (re email). In my email I had written "Ok then, enjoy your weekend and convey my regards to your family.". So you say that I don't have to feel bad and apologize? I know him for past 5 months and our relationship is not very casual but fine.
You don't need to worry about it

CliveEmotion: smile
Dear Clive, that's a relief. Thanks again. Have a wonderful weekend Emotion: happy.
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you see, it depends on how you use it. if you use it a conversation and youuu look annyoed than that can be taken offensivly. if youu are eamiling someone than like [a boss} he wont take it o