AQL Example

For example, if a 5,000-piece lot requires a 200-piece sample and allows up to 10 major defects, the batch passes when 8 are found and fails when the defect count reaches 11.

Example Lot Size

Suppose a factory produces a shipment of 5,000 products. The buyer wants the batch checked before shipment, so the inspector uses the lot size to find the correct sample size from the AQL chart.

Sample Selection

Instead of checking all 5,000 products, the inspector selects a smaller sample from different cartons or production areas. This sample must represent the full batch so the inspection result can support a fair pass or fail decision.

Inspection Level

The inspection level decides how many products should be checked from the lot. A normal inspection level may be used when the product risk is standard and there is no serious quality history with the supplier.

Defect Categories

During the inspection, defects are grouped as critical, major, or minor. A broken safety part may be critical, a wrong size may be major, and a small scratch may be minor, depending on the buyer’s quality rules.

Acceptance Number

The acceptance number shows how many defects are allowed in the sample. For example, if the accepted number for major defects is 10, the batch can pass when the inspector finds 10 or fewer major defects.

Rejection Number

The rejection number shows when the batch fails. If the rejection number is 11 and the inspector finds 11 major defects, the batch fails because the defect count has crossed the allowed quality limit.

Pass Result

If the inspector checks the sample and finds 8 major defects while the accepted number is 10, the batch can pass for major defects. The defect count stays within the allowed limit set by the selected AQL level.

Fail Result

If the inspector finds 12 major defects while only 10 are allowed, the batch fails inspection. The buyer may ask the supplier to sort defective items, repair the products, repeat inspection, or hold the shipment.

Final Decision

The final AQL decision depends on the sample result, defect category, acceptance number, and rejection number. This example shows how inspectors use a fixed sampling rule to judge whether a full batch meets the agreed quality standard.

For the basic definition and meaning behind this inspection example, read the complete guide on AQL full form.