AQL Final Random Inspection: Sampling Plans and Critical Defects
AQL defines how many pieces to inspect and how many defects are acceptable, and the definitions matter as much as the numbers.
The practical guidance below is written for buyers and product developers who need a specification that a mill can meet.
Sampling plans
Inspection levels and AQL values determine the sample size and the acceptance or rejection number for each defect class.
Experience shows that small specification decisions here have an outsized effect on the customer experience.
Defect classification
Critical defects affect safety or legality, major defects affect saleability, and minor defects affect appearance only.
Agree the tolerance in writing before sampling, since tolerance disputes are far more common than outright failures.
- Confirm the numeric range and the test method in the specification
- Keep an approved physical standard at the machine
- Retest after the agreed care regime before shipping
Common major defects
Measurement outside tolerance, wrong shade, broken stitching and incorrect trimming are typical findings.
Where several lines produce the same style, align settings across lines before the order starts.
Inspection execution
Pieces are drawn randomly from finished cartons, measured and compared against the approved sample.
Where a claim will be published, check that the test method supports the exact wording used in marketing.
- Request test reports on production fabric, not on development samples
- Verify the sampling plan and the number of specimens
- Store reports with roll or lot identification for traceability
Outcome management
Failed inspections require a documented corrective action plan, re-inspection or rework before shipment.
Agree how changes will be priced before the order starts, which avoids difficult conversations mid-production.
Summary
Used as a checklist in development and again before shipment, the points above prevent the most common and most expensive failures.
