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AQL Inspection Calculator

Plan an indicative General Inspection Level II sample and record the defects found before shipment. Always release goods using the buyer-approved sampling standard and defect classification.

Calculate online

Enter your production values to calculate an operational estimate.

  • Inspection lot size
  • AQL level
  • Defects found

Calculation method

Plan a garment inspection sample from lot size and AQL, then compare defects found with an indicative acceptance threshold.

Method: sample size follows General Level II lot bands; planning acceptance ≈ sample size × AQL %

Worked example: 3200 pcs, AQL 2.5 for major defects

Inspection lot size 3200 falls in the 3201-10000 band under G-II. Use this to plan inspector days before the final AQL table check.

  1. Sample size (G-II): 125 pcs for lot 3200
  2. Planning threshold at AQL 2.5 ≈ 125 × 0.025 = 3.1. Use as early signal only.
  3. If 4 major defects found, hold shipment and re-check against ISO 2859-1 acceptance number (5 for this band) and buyer classification of critical/major/minor.

Critical defects often use AQL 0 or 100% inspection. Confirm critical/major/minor definitions with the buyer before counting.

Frequently asked questions

What does AQL mean?

Acceptance Quality Limit is a sampling parameter used with an approved inspection plan. It is not permission to manufacture a fixed percentage of defects.

Can this calculator replace an ISO or ANSI sampling table?

No. It is an early planning aid. Use the buyer-approved ISO 2859-1 or ANSI/ASQ Z1.4 table for final sample and acceptance numbers.

What is the difference between AQL 1.0, 2.5 and 4.0?

Lower AQL means tighter quality — fewer defects allowed for the same sample. AQL 1.0 is stricter than 2.5. Use the buyer's specified AQL per defect class.

What sample size for 500 vs 5000 garments?

Under G-II: 500 pcs → 50 samples, 3200 pcs → 125 samples, 10000 pcs → 200 samples. Larger lots need proportionally smaller sampling percentages.

Do I count minor defects the same as major?

No. Most buyers set separate AQLs — e.g. AQL 1.5 for major, 4.0 for minor. Classify each defect before comparing to its threshold.

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