How to read an AQL inspection report
What the numbers mean, how a lot passes or fails, and what to ask when it fails.
By BizShip International, Lahore | Buyer guide | 7 min read
An AQL inspection report tells you whether your goods passed a final inspection before shipment, and why. It is one of the most useful documents in textile sourcing, but only if you know how to read it. This guide walks through each part of a typical report, explains the numbers, and shows what to do when a lot fails.
Key points
- AQL is a sampling method: the inspector checks a random sample, not every piece.
- Major and minor defects are judged separately; failing either one fails the lot.
- A pass means the defect rate is acceptable, not that there are no defects.
- Read the photos and measurements, not only the result line.
What AQL means
AQL stands for Acceptance Quality Limit. Instead of checking every piece, the inspector draws a random sample whose size depends on the size of the lot, using the sampling tables of ISO 2859-1. The sample is checked against your approved sample and specification, every defect is counted and classified, and the totals are compared with the limits for each defect class.
Most textile buyers use General Inspection Level II, with AQL 2.5 for major defects and AQL 4.0 for minor defects. Critical defects, which make a product unsafe or illegal to sell, are usually not accepted at all.
The parts of an AQL inspection report
Reports differ in layout, but a good one always contains these parts:
- Order details: buyer, factory, product, style, color, order quantity and the lot quantity presented for inspection.
- Sampling plan: inspection level, sample size, and the accept and reject numbers for each defect class.
- Defect summary: how many critical, major and minor defects were found, with a short description of each type.
- Measurements: sizes checked against your size chart or specification, with tolerances.
- Product checks: weight or GSM, color against the approved sample, labels, function and any special checks you asked for.
- Packing and marking: carton count, carton marks, barcodes, packing method and assortment.
- Photos: the product, each defect type, labels, packing and cartons.
- Result: passed, failed, or pending your decision, with the inspector’s comments.
Reading the numbers: a worked example
Say a factory presents 3,000 bath towels for final inspection, at Level II with AQL 2.5 for majors and 4.0 for minors. The sampling table gives a sample of 125 towels and these limits:
| Line on the report | Example | What it tells you |
|---|---|---|
| Lot size | 3,000 pieces | The quantity ready for shipment when the inspector arrived |
| Inspection level | General II | How large a sample to draw; Level II is the usual default |
| Sample size | 125 pieces | How many pieces were checked, drawn at random |
| Major, AQL 2.5 | Accept 7, reject 8 | Up to 7 major defects allowed; 8 or more fails the lot |
| Minor, AQL 4.0 | Accept 10, reject 11 | Up to 10 minor defects allowed; 11 or more fails the lot |
| Critical | Accept 0 | Any critical defect fails the lot |
Figures from the ISO 2859-1 single sampling tables, normal inspection, for a lot of 1,201 to 3,200 pieces.
The inspector finds 5 major defects (two holes, three stains) and 12 minor defects (loose threads and uneven hems). The majors are within the limit of 7, but the minors are above the limit of 10. The lot fails, even though the major defects passed. Each class is judged on its own.
What a pass does not mean
A pass means the defect rate in the lot is likely to be within the level you agreed. It does not mean the lot has no defects. The defective pieces found in the sample should still be replaced or repaired before packing, and a good report says that this was done.
Also check that the sample was drawn at random from cartons across the whole lot, not from one pile the factory prepared. The report should say how the cartons were selected.
What to do when a lot fails
- Rework and re-inspect: the factory sorts and repairs the goods, and the lot is inspected again. This is the usual route.
- Sort 100%: every piece is checked and defective pieces are removed or replaced, then the lot is re-inspected.
- Accept with conditions: for minor issues only, you may accept the lot with a discount or other agreed terms. This is your decision, not the inspector’s.
- Reject: if the defects are serious and cannot be fixed, the lot is rejected under your contract terms.
Whatever you decide, decide before the balance is paid and before the goods leave the factory.
Questions to ask about any AQL inspection report
- Which inspection level and AQL values were used, and do they match the order?
- Was the sample drawn at random from cartons across the whole lot?
- How many pieces were measured, and were any measurements outside tolerance?
- Is there a photo of every defect type?
- Were the defective pieces from the sample replaced?
- Was the report shared with you before the balance payment and shipment?
At BizShip, our own inspectors carry out the final AQL inspection on every order and you receive the report with photos before your goods ship. You can see our process on our Quality Control page.
Questions buyers ask
Is AQL 2.5 good enough for textiles?
For most textile products, AQL 2.5 for major defects and 4.0 for minor defects is the common standard. For premium or sensitive products you can ask for a stricter level, such as AQL 1.5 for majors, which means a lower limit.
Who decides what counts as a major or minor defect?
It should be agreed before production, in a defect list attached to your order. The inspector then classifies defects against that list, so there are no arguments after the inspection.
When should the final inspection happen?
When production is complete and at least 80% of the goods are packed, so the sample can be drawn from the real shipment cartons.
Want this done for your order?
BizShip inspects every order with our own team and shares the report with photos before your goods ship. Send us your product and quantity, and we reply within one business day.