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Short answer: for a 2,000-piece lot at the normal inspection level, the inspector pulls 125 pieces at random. With AQL 2.5 for major defects, the lot passes if 7 or fewer of those have a major defect, and fails at 8. AQL is a sampling rule. It is not a promise that exactly 2.5 percent of your order is defective.
The numbers by order size
Your order size
200
pieces checked
≤10
major defects pass
11+
fail the lot
200 of 5,000 pieces, about 4.0%. They are pulled at random from many cartons.
The lot passes.
Using general inspection level II, the usual choice:
| Order size | Pieces inspected | Major defects, AQL 2.5: pass up to | Fail at |
|---|---|---|---|
| 281 to 500 | 50 | 3 | 4 |
| 501 to 1,200 | 80 | 5 | 6 |
| 1,201 to 3,200 | 125 | 7 | 8 |
| 3,201 to 10,000 | 200 | 10 | 11 |
| 10,001 to 35,000 | 315 | 14 | 15 |
Minor defects are usually judged at AQL 4.0, which allows more: 10 in a sample of 125.
The AQL inspection calculator gives the sample size and limits for any quantity.
Three kinds of defect
| Class | Meaning | Towel and sheet examples | Usual limit |
|---|---|---|---|
| Critical | Unsafe, or breaks the law | A broken needle in a hem, mould | Zero. One fails the lot |
| Major | A customer would reject or return it | A hole, a stain, wrong size, open seam, wrong colour | AQL 2.5 |
| Minor | A flaw most customers would not notice | A loose thread end, a slightly crooked label | AQL 4.0 |
Agree the defect list in advance. Whether a pulled loop is major or minor should not be decided on inspection day.
What "pass" really means
Seven major defects in 125 is 5.6 percent of the sample. So why is it called 2.5?
AQL 2.5 means a lot whose true defect rate is 2.5 percent will pass almost every time. A lot that is much worse will usually fail. The pass limit is set with a margin, because a random sample can be unlucky.
What this means for you:
- A passed lot is very unlikely to be badly defective.
- A passed lot is not defect-free. On 2,000 pieces, expect to find a few dozen pieces with some flaw if you check every one.
- AQL protects against bad lots. It does not sort good pieces from bad.
Planning for the flawed pieces
- Hotels: order a little over par. Flawed pieces become the first rags.
- Retail brands: inspect every piece before it goes to a customer, or agree a tighter AQL, or ask the supplier to sort 100 percent. Both cost more.
- Everyone: agree in advance what happens to defective pieces found after delivery, above an agreed rate.
Tighter and looser
| AQL for major defects | Used for |
|---|---|
| 1.0 or 1.5 | Premium retail, where every piece is individually sold |
| 2.5 | The usual standard for hotel and general consumer textiles |
| 4.0 | Low-cost institutional goods |
A tighter AQL means more of the supplier's production is rejected before it reaches you, which is why it costs more.
Beyond counting defects
A full inspection also checks measurements, weight, colour against the approved sample, labels, packing and carton marks, and counts cartons. Read the whole report, not only the pass line.
What we do
Every order is inspected to AQL 2.5 before dispatch, and you receive the report and production photos before the balance is due. Your own inspector is welcome. See inspect before you pay.
For the principles, read AQL 2.5 explained. To place an order with the defect list agreed upfront, ask us for a quote.
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Written by
Dr Abin Babu
Founder & Chairman, Anabyn Global Ventures
Anabyn exports hotel and home linen from Kerala, India. These guides come from the questions buyers ask our desk. About the team
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