A 38,000 pcs jacket order failed final inspection at AQL 2.5 with 14 major defects, mostly zipper puller detachment traced to a trim lot changed during the shift without a written handover.
The night in-charge told the day in-charge verbally; nothing was recorded, so QC inspected against the original trim card. The buyer learned three days later, and the factory lost the discount negotiation because it had no written trail of when the change was known.