AQL Inspection

Scope

• ›Finished-garment (pre-shipment) and in-line audits.
• ›Attribute inspection using ISO 2859-1 / ANSI/ASQ Z1.4 single-sampling plans.
• ›Cartons drawn using ISO 2859-1 general inspection level II unless otherwise agreed.
• ›Critical, major and minor defect classification aligned to the buyer's approved defect list.

Cost & implementation difficulty

Not yet verified. Independently verified evidence is not available on this site. This section will be published only when a public reference exists.

Steps

1. Agree AQL levels per defect class with the customer BEFORE lot presentation (e.g. 0/2.5/4.0).
2. Determine lot size from packed cartons; select sample size using ISO 2859-1 Table 1 and 2A.
3. Randomise carton selection using √N + 1 for carton-draw and pull garments by random sampling within.
4. Inspect against the approved specification sheet, colour standard and workmanship standard.
5. Record every defect against a coded checklist; distinguish critical / major / minor.
6. Compare accumulated defects to accept/reject numbers; issue a written disposition.

Risks

• ›Using inspection level or AQL that does not match the buyer's approved plan.
• ›Sampling from a single carton or the top layer only — non-random draw.
• ›Classifying critical defects as major to keep the lot within Ac.
• ›Re-inspecting rejected lots without a documented rework and re-presentation step.

Evidence & records

• ›Signed AQL inspection report with lot size, sample size, plan and Ac/Re numbers.
• ›Coded defect log tied to the buyer's defect classification list.
• ›Photographic evidence for each critical / major defect found.
• ›Traceability to production batch, sewing line and inspector ID.

Case study

Not yet verified. Independently verified evidence is not available on this site. This section will be published only when a public reference exists.

Author & last reviewed

Authored by Sanjeewa Dehiwalage.

Last reviewed: 2026-07-17