AQL Inspection Levels Explained
Quick Definition: AQL (Acceptable Quality Level) is a statistical sampling method used in quality inspection. It determines how many units to inspect from a batch and how many defects are acceptable before rejecting the shipment.
How AQL Works
- Define batch size: Total units in the production run.
- Select inspection level: Usually General Inspection Level II (standard).
- Look up sample size: The AQL table tells you how many units to inspect.
- Set AQL limits: Typically AQL 2.5 for major defects and AQL 4.0 for minor defects.
- Inspect and count defects: If defects exceed the accept number, reject the batch.
Common AQL Levels
| AQL Level | Meaning | Used For |
|---|---|---|
| AQL 0 | Zero tolerance for critical defects | Safety hazards, electrical dangers |
| AQL 1.0 | Very strict | High-value products, medical devices |
| AQL 2.5 | Industry standard | Most consumer products — the default for major defects |
| AQL 4.0 | Relaxed | Minor cosmetic defects |
Sample Size Example (AQL 2.5, Level II)
| Batch Size | Sample Size | Accept | Reject |
|---|---|---|---|
| 501–1,200 | 80 | 5 | 6 |
| 1,201–3,200 | 125 | 7 | 8 |
| 3,201–10,000 | 200 | 10 | 11 |
Example: For a batch of 2,000 units, you inspect 125 units. If you find 7 or fewer major defects, the batch passes. If you find 8 or more, it fails.
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