AQL stands for acceptable quality limit. It is the maximum number of defective garments that an inspector will accept in a random sample drawn from a finished lot, and if the sample contains more defects than the limit the lot is rejected or reworked. For most garment orders the common setting is AQL 2.5 for major defects and AQL 4.0 for minor defects, with zero tolerance for critical defects. Stricter settings such as AQL 1.0 for majors are used for higher-priced goods or for buyers with strict return policies.
How the sample size is set
The inspector does not choose the sample size. It comes from the standard sampling tables, published as ISO 2859-1 and ANSI/ASQ Z1.4, which link the size of the lot to a code letter and then to a sample size. Most garment inspections use general inspection level II, which is the default balance between inspection effort and confidence.
The tables give, for each sample size and AQL, an accept number and a reject number. If the number of major defects found is at or below the accept number the lot passes on majors, and the same test is applied separately to minors. A lot can therefore fail on minors even when it passes on majors.
The sample is drawn at random from across the lot, across sizes, colours and cartons, so the result reflects the whole shipment rather than the best cartons placed near the door.
What the common levels mean in practice
- AQL 2.5 for majors and 4.0 for minors is the usual setting for mid-market fashion and basics.
- AQL 1.0 or 1.5 for majors is typically used for premium garments, workwear and uniforms.
- AQL 4.0 for majors and 6.5 for minors is sometimes accepted for low-cost promotional goods.
- Critical defects, such as a broken needle in a garment or a wrong care label, are zero tolerance at every AQL level.
Choosing a level for your order
Start from your market and your cost of a return. If a defective garment reaches a customer and comes back by courier, the cost usually far exceeds the price of tighter inspection, so a stricter AQL pays for itself. If the goods are low-value and sold in bulk, the common 2.5 and 4.0 levels are usually sufficient.
Write the AQL, the inspection level and the defect classification into your purchase order and your inspection brief. The factory should know before it starts production what the lot will be judged against, and the inspector should be working from the same document.
Remember that AQL is a statistical limit, not a promise that every garment is perfect. A lot passed at AQL 2.5 can still contain a small percentage of defective pieces, which is why inline inspection during production matters as much as the final check.
How Creston & Co helps
We agree the AQL and defect list with you before production starts, carry out inline and final random inspection against the ISO 2859-1 tables, and send you a report with photographs the same day. We also seal approved samples so that the inspector has a reference to compare against. A free 20-minute sourcing review is a good place to settle which level suits your range.