AQL Sampling Calculator
Calculate inspection sample size and acceptance numbers using ISO 2859-1 / ANSI Z1.4 single-sampling plan, General Inspection Level II, normal inspection — the global standard used by every major third-party inspection company.
Inspection Parameters
Total quantity to be inspected (e.g. order quantity).
Safety, legal, regulatory hazards. Industry standard: AQL 0.
Functional / saleability defects. Industry standard: AQL 2.5.
Cosmetic imperfections. Industry standard: AQL 4.0.
Inspection Plan
Code Letter
J
Sample Size
80
units to inspect
Maximum Defects Allowed (Accept Number)
The lot is accepted if defects in the inspected sample are ≤ Accept Number for each class. Otherwise the lot is rejected and requires rework, sorting or replacement.
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AQL Quick Reference (ISO 2859-1, Level II)
| Lot Size | Code | Sample | AQL 1.0 (Ac/Re) | AQL 2.5 (Ac/Re) | AQL 4.0 (Ac/Re) |
|---|---|---|---|---|---|
| 2 – 8 | A | 2 | 0 / 1 | 0 / 1 | 0 / 1 |
| 9 – 15 | B | 3 | 0 / 1 | 0 / 1 | 0 / 1 |
| 16 – 25 | C | 5 | 0 / 1 | 0 / 1 | 1 / 2 |
| 26 – 50 | D | 8 | 0 / 1 | 1 / 2 | 1 / 2 |
| 51 – 90 | E | 13 | 0 / 1 | 1 / 2 | 2 / 3 |
| 91 – 150 | F | 20 | 1 / 2 | 2 / 3 | 3 / 4 |
| 151 – 280 | G | 32 | 1 / 2 | 3 / 4 | 5 / 6 |
| 281 – 500 | H | 50 | 2 / 3 | 5 / 6 | 7 / 8 |
| 501 – 1,200 | J | 80 | 3 / 4 | 7 / 8 | 10 / 11 |
| 1,201 – 3,200 | K | 125 | 5 / 6 | 10 / 11 | 14 / 15 |
| 3,201 – 10,000 | L | 200 | 7 / 8 | 14 / 15 | 21 / 22 |
| 10,001 – 35,000 | M | 315 | 10 / 11 | 21 / 22 | 21 / 22 |
| 35,001 – 150,000 | N | 500 | 14 / 15 | 21 / 22 | 21 / 22 |
Ac = Accept number (max defects allowed). Re = Reject number. Based on single-sampling plan, normal inspection, General Inspection Level II.
Frequently Asked Questions
What is AQL in quality inspection?▾
AQL (Acceptable Quality Level) is the maximum percentage of defective items considered acceptable in a sample lot during inspection. It is defined by international standard ISO 2859-1 (equivalent to ANSI/ASQ Z1.4). The lower the AQL, the stricter the inspection. AQL 0 means zero tolerance (used for critical/safety defects), while AQL 6.5 is lenient (used for minor cosmetic issues).
What AQL levels should I use for my products?▾
Industry-standard defaults for consumer goods are: Critical defects = AQL 0 (zero tolerance — safety, regulatory, legal hazards), Major defects = AQL 2.5 (functional failures, visible defects affecting saleability), Minor defects = AQL 4.0 (cosmetic imperfections not affecting function). Stricter AQLs (1.0 / 1.5) are common for premium brands, electronics, baby products and medical devices.
How is the sample size determined?▾
Sample size is based on the lot size and inspection level (typically General Inspection Level II for normal inspection). For example, a lot of 1,200 units uses code letter J with a sample of 80 pieces; a lot of 10,000 units uses code letter L with a sample of 200 pieces. The inspector randomly selects this sample from the entire production batch.
What does 'Ac' (accept number) mean?▾
Ac is the maximum number of defects allowed in the sample for the lot to pass. If defects found ≤ Ac, the lot is accepted. If defects > Ac (the 'Re' or reject number), the entire lot is rejected and either reworked, sorted 100%, or replaced. Each defect class (critical/major/minor) has its own Ac number.
Is AQL the same as defect rate?▾
No. AQL is a sampling tolerance, not a guaranteed defect rate. A lot accepted at AQL 2.5 may still contain defects — AQL only ensures that lots above a certain quality level are usually accepted and lots below it are usually rejected. For zero-defect requirements, use 100% inspection or AQL 0.
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