AQL Sampling Simulator

AQL Sampling Simulator

The Three Steps to Utilizing AQL

Step 1: Select Your Inspection Level

The "General Inspection Level" dictates the number of units selected from your total order quantity. This establishes a balance between inspection costs and the potential risk of defects.

• Level I (Reduced Inspection): Inspects fewer units and is most suitable for suppliers with a proven track record of high quality.

• Level II (Normal Inspection): Represents the industry standard and is utilized for the majority of inspections unless otherwise stated.

• Level III (Tightened Inspection): Involves inspecting a greater number of units and is recommended for new suppliers, high-value goods, or re-inspections following a failure.

Step 2: Establish Your Acceptance Quality Limits (AQL)

It is important to recognize that not all defects are of equal significance. We categorize defects into three classifications, each having a defined tolerance limit.

• Critical Defects (0.0): Indicates total failure or unsafe conditions (e.g., needles improperly left in garments, mold, insects) or non-compliance with regulations. Zero Tolerance.

• Major Defects (2.5): Factors that affect the functionality or saleability of the product (e.g., open seams, incorrect measurements, permanent stains).

• Minor Defects (4.0): Cosmetic discrepancies that do not fundamentally impact the product's usability (e.g., untrimmed threads, slight variations in color).

Step 3: Interpret the Results

Using the AQL Tables, we ascertain the "Accept" and "Reject" thresholds.

• Example: For a lot consisting of 5,000 units at Level II, we conduct an inspection of 200 samples.

• If we identify 10 Major defects, the shipment PASSES (Limit is 10).

• If we discover 11 Major defects, the shipment FAILS (Reject is 11).

Application of AQL to Your Inspection Checklist

At 2needle, we implement the AQL standard across three essential pillars of garment inspection:

1. Visual Workmanship (Appearance)

Visual inspection constitutes the foundation of AQL. We evaluate the sample size for both cosmetic and construction issues.

• Criteria for Evaluation: Stitching quality, fabric imperfections, cleanliness, color harmony, and attachment of accessories (buttons, zippers).

• The Impact of AQL: By systematically classifying defects as Major or Minor, we eliminate subjective interpretations. A defect is logged against the AQL limit irrespective of the factory's perspective.

2. Measurement & Fit (Dimensional Verification)

For apparel, accurate measurements are as crucial as well-finished seams.

• Criteria for Evaluation: We assess specific measurement points (POM) such as chest, length, sleeve, and neck opening against your Spec Sheet.

• The Impact of AQL: Measurements that exceed your specified tolerances (typically +/- 0.5" or 1cm) are classified as Major Defects. If a significant number of pieces are out of specification, the AQL limit is violated, resulting in the rejection of the lot due to sizing discrepancies.

3. Packing & Packaging (Compliance)

Your product must arrive securely and comply with retail standards.

• Criteria for Evaluation: Assortment (size/color distribution), barcode scannability, carton weight, shipping labels, and polybag safety warnings.

• The Impact of AQL: Packaging errors are often categorized as Critical or Major, as they influence your ability to sell or stock the products. We ensure that both the outer carton and inner packaging adhere to stringent retailer requirements prior to departure from the factory.

Need assistance determining your AQL?

Unsure whether you require Level II or Level III?

Utilize our interactive tool or reach out to us for a complimentary consultation.