ISO 2859-1 · ANSI/ASQ Z1.4
AQL Inspection Explained & Booked in India
AQL (Acceptable Quality Limit) inspection is a statistical sampling check where an inspector pulls a defined sample from a finished lot and accepts or rejects the whole shipment against agreed defect limits — commonly AQL 2.5 for major defects. We run AQL 1.0 / 1.5 / 2.5 / 4.0 inspections across 15+ Indian manufacturing hubs. ISO 2859-1 sampling, ISO 17020-aligned methodology, 24-hour photo reports accepted by US, UK, EU, AU and JP retailers.
AQL sample size chart (ANSI/ASQ Z1.4, General Level II)
The sample size and accept/reject numbers US and EU retailers use most often. At AQL 2.5, "Accept 5" means the lot passes with up to 5 major defects in the sample and fails at 6.
| Lot size (units) | Code letter | Sample size | AQL 2.5 accept / reject | AQL 4.0 accept / reject |
|---|---|---|---|---|
| 151 – 280 | G | 32 | 2 / 3 | 3 / 4 |
| 281 – 500 | H | 50 | 3 / 4 | 5 / 6 |
| 501 – 1,200 | J | 80 | 5 / 6 | 7 / 8 |
| 1,201 – 3,200 | K | 125 | 7 / 8 | 10 / 11 |
| 3,201 – 10,000 | L | 200 | 10 / 11 | 14 / 15 |
| 10,001 – 35,000 | M | 315 | 14 / 15 | 21 / 22 |
Critical defects are almost always set at AQL 0 — a single critical finding rejects the lot regardless of sample size.
AQL levels — which one should you use?
The level you choose determines how many defects the sample is allowed to contain before the entire lot is rejected.
| AQL Level | Use case | Notes |
|---|---|---|
| AQL 0 | Critical defects | Zero tolerance. Safety hazards, regulatory non-compliance (CPSIA lead, sharp edges, fire risk). Any critical defect = automatic fail. |
| AQL 1.0 | Strict — premium goods | Used for high-value electronics, medical devices, luxury fashion. Allows 5 majors in a 200-unit sample at most. |
| AQL 1.5 | Tight consumer goods | Used by major US/EU retailers (Target, M&S, John Lewis) for apparel and home goods. Allows 7 majors per 200-unit sample. |
| AQL 2.5 | Standard consumer goods | The most common AQL level worldwide — covers ~80% of all third-party inspections. Accept 10 / reject 11 majors in a 200-unit sample. |
| AQL 4.0 | Loose / minor defects | Used for low-value, low-risk goods or for tracking minor cosmetic defects separately from majors. Accept 14 / reject 15 in a 200-unit sample. |
| AQL 6.5 | Very loose | Rare. Used for industrial / construction goods where small cosmetic defects don't affect fitness for use. |
Standards we follow
ISO 2859-1:1999
International standard for sampling procedures for inspection by attributes. Defines the sample size codes, inspection levels (I, II, III) and switching rules between Normal / Tightened / Reduced inspection.
ANSI/ASQ Z1.4
The US standard — substantively identical to ISO 2859-1 and used by Walmart, Target, Amazon and most US retailers. Our reports cite both standards by default.
ISO 17020
Defines the competence requirements for inspection bodies. Our inspection process and inspector qualifications align with ISO 17020 Type A (third-party independent) principles.
Defect classification
Each defect is classified as Critical (safety/regulatory), Major (functional/visible affecting saleability), or Minor (cosmetic, doesn't affect function). Buyer-specific defect lists are honoured.
AQL FAQs
What is AQL inspection?
AQL (Acceptable Quality Level) inspection is a statistical sampling method defined in ISO 2859-1 and ANSI/ASQ Z1.4. It tells the inspector how many units to pull from a lot and how many defects of each class (critical / major / minor) are acceptable before the entire lot is rejected. AQL inspection is the global standard for third-party quality inspection in textile, consumer electronics, homeware, footwear and engineering goods.
What AQL level should I use?
Use AQL 0 for critical defects (always zero), AQL 2.5 for major defects on standard consumer goods (the global default), AQL 4.0 for minor defects. Use AQL 1.5 for major defects on premium goods sold to tight retailers (Target, M&S, John Lewis). Use AQL 1.0 only for high-value or safety-sensitive products like medical devices and lithium-ion batteries.
How big is the AQL 2.5 sample?
For a lot of 3,201–10,000 units, ISO 2859-1 / ANSI Z1.4 General Level II requires a sample size of 200 units. At AQL 2.5 up to 10 major defects are accepted (lot passes) and 11+ rejects the lot; at AQL 4.0 the accept number is 14. Use our free AQL calculator at /resources/aql-calculator to compute the exact sample size and accept/reject numbers for any lot size and AQL level.
Are your AQL inspection reports accepted by US, EU and UK retailers?
Yes. Our AQL reports cite both ISO 2859-1 and ANSI/ASQ Z1.4 and follow the format used by Walmart, Target, Amazon, Tesco, Sainsbury's, M&S, John Lewis, Coles and Woolworths. Reports include photo evidence per defect, classification, measurement records, AQL accept/reject calculation, and a clear pass/fail recommendation accepted by Letter-of-Credit banks and freight forwarders.
What's the difference between AQL 2.5 and 100% inspection?
AQL 2.5 is statistical sampling — 200 units checked out of (say) 10,000. 100% inspection means every single unit is checked. 100% inspection is 30–50× more expensive and is reserved for: critical safety defects, very small lots (<200 units), or when AQL inspection has already failed and the lot is being reworked. For 99% of buyers AQL 2.5 sampling is the right balance of cost and risk control.
How much does an AQL inspection cost?
In India a third-party AQL inspection is billed per man-day: $250–$400 per inspector-day for most consumer goods, covering up to 8 hours on site including travel within the city. A typical 3,200–10,000 unit lot needs one man-day. Add roughly $80–$150 for outstation travel, and lab testing (CPSIA, Prop 65, REACH) is quoted separately. US buyers usually pay by card or wire in USD and receive the photo report within 24 hours of the site visit.
Can a US buyer book an AQL inspection in India remotely?
Yes. Send the PO, packing details, factory address and your defect list; we schedule an inspector within 24–48 hours, run the AQL 2.5 check under ANSI/ASQ Z1.4, and deliver a photo-documented pass/fail report you can act on before the balance payment is released and before the container is sealed. No travel to India is required.
Do you have a free AQL chart and calculator?
Yes — we publish the free AQL 2.5 sampling chart at /blog/aql-inspection-levels-guide and a free interactive AQL calculator at /resources/aql-calculator. Both are referenced by procurement teams worldwide and need no signup.
Inspection & Audit Hub
Complete Quality Inspection Services in India
Independent third-party inspections and factory audits across 15+ Indian manufacturing hubs — supporting buyers in the US, UK, EU, Australia, Canada and UAE since 1994.
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