Define the lot
Confirm the shipment quantity, product scope, inspection type and whether the lot is ready for sampling.
AQL sampling
Acceptance Quality Limit, explained for real inspections.
AQL is the standard sampling logic used in many product inspections. Instead of checking every unit, the inspector checks a statistically defined sample from the production lot. The lot is accepted or rejected based on the number and severity of defects found in that sample.
Mega Step uses AQL as a decision framework for pre-shipment inspections, during-production checks and loading checks when the customer wants clear pass, fail or pending criteria before goods leave the factory.
How it works
The AQL table turns lot size into an inspection decision.
AQL tables use two steps: first use the lot size and inspection level to find a sample size code letter, then use that code letter with the agreed AQL value to find the sample size, acceptance number (Ac) and rejection number (Re). If defects reach the rejection number, the lot fails under that defect class.
Choose the inspection level
For most consumer goods, General Inspection Level II is the normal starting point. Level I lowers sample size; Level III increases it.
Find the sample size code
The lot size and inspection level lead to a letter code in the AQL table. That code defines how many units are checked.
Apply the AQL limits
The agreed AQL values for critical, major and minor defects define the acceptance and rejection numbers.
Report the result
Mega Step records checked quantity, defect class, AQL result, photos and comments in the inspection report.
Example
A simple buyer-side example.
For a lot between 3,201 and 10,000 pcs under General Inspection Level II, the sample size code is typically L. Under normal inspection this means 200 units are drawn randomly from the lot. If the agreed major-defect AQL is 2.5, the lot is accepted with 10 or fewer major defects and rejected at 11 major defects.
This does not mean the full shipment has only ten defects. It means the sample result is within or outside the agreed statistical tolerance for that lot.
Sample calculation
- Lot size
- 3,201-10,000 pcs
- Inspection level
- General II
- Sample size code
- L
- Sample size
- 200 random pcs
- Major AQL 2.5
- Accept 10 / Reject 11
- Minor AQL 4.0
- Accept 14 / Reject 15
Defect classification
AQL only works when defects are classified before inspection.
Usually 0 allowed
Critical
Safety, legal compliance, sharp edges, fire risk, wrong warning labels or failures that make the product unsafe.
Commonly AQL 2.5
Major
Defects likely to affect saleability, function, assembly, appearance expectations or customer acceptance.
Commonly AQL 4.0
Minor
Workmanship or cosmetic issues that do not normally prevent use but exceed agreed quality expectations when repeated.
What AQL is good for
AQL gives procurement and quality teams a consistent sampling method. It is useful when full inspection is too slow, too expensive or not required, and when the buyer needs a documented pass/fail decision based on agreed defect limits.
What AQL does not do
AQL is not a guarantee that every unit in the shipment is defect-free. It is a risk-based sampling method. High-risk products, safety-critical requirements, regulatory checks or repeated supplier problems may require tighter levels, special checks, lab testing or 100% inspection.
How Mega Step reports it
In a Mega Step inspection report, the AQL setup is connected to the inspected quantity, sample size, defect list, photo evidence and final conclusion. When Qarma online reporting is used, customers can review the AQL result together with checklist answers and defect photos.
Reference basis: QualityInspection.org AQL explanation and standard ISO 2859-1 / ANSI Z1.4 sampling practice.