Quality template
A final inspection record with the sampling plan in the header, defects listed by critical, major and minor class, totals, and an automatic pass or fail against the accept numbers.
The AQL inspection sheet records a final inspection. The header holds the order details and the sampling plan: sample size and accept numbers for major and minor defects. Each defect found is listed with its count by class. The summary totals critical, major and minor defects and compares them with the accept numbers to give a pass or fail result.
The example values (lot 3,000, sample 125, accept 7 major and 10 minor) match a common plan at general inspection level II with AQL 2.5 major and 4.0 minor. Replace them with the plan in the buyer's manual. Use the AQL sample size calculator to look up plans.
The result formula fails the lot for any critical defect, and otherwise passes only if both major and minor totals are within the accept numbers. Some buyers use different rules (for example, a separate critical AQL). Adjust the formula if your buyer's manual differs.
The Excel workbook contains the totals and result formula. The CSV contains headings only.
| Field | What to enter |
|---|---|
| PO, style and lot size | Identify the lot being inspected. |
| Sample size and accept numbers | From the buyer's sampling plan: sample size and the accept numbers for major and minor defects. |
| Defect description | One row per defect type found, using the buyer's defect names. |
| Critical, major, minor | Count of that defect in each class. |
| Totals and result | Calculated totals by class and a PASS or FAIL result. Any critical defect fails the lot unless the buyer's manual says otherwise. |
AQL sampling decides how many garments to inspect from a lot and how many defects are allowed. How the sampling tables work, inspection levels, code letters, accept and reject numbers, and what AQL does and does not guarantee.
A final (pre-shipment) inspection checks a finished, packed lot against the buyer's requirements before it ships. What is checked, how samples are drawn, the order of work, and how to prepare so the lot passes the first time.
Inline inspection checks work at or near each operation while the line is running. How the traffic light system works, how to choose operations to check, sample sizes and frequency, and how to act on the results.
An overview of the sewing defects that cause most repairs and rejections, grouped by stitch, seam and assembly problems, with the usual causes and where to look first.