AQL Chart and Table: How to Read the AQL Sampling Chart for Product Inspection
AQL Chart and Table: How to Read the AQL Sampling Chart for Product Inspection The AQL chart tells you how many products to inspect and how many defects are allowed.
AQL Chart and Table: How to Read the AQL Sampling Chart for Product Inspection
The AQL chart tells you how many products to inspect and how many defects are allowed. Here is how to read it step by step.
The AQL chart, also called the AQL table, is the most important tool in product inspection. It tells you two things: how many units to check and how many defects are acceptable.
Without the AQL chart, you are guessing. With it, you have a clear standard backed by international quality norms.
This guide explains how to read the AQL sampling chart. It covers AQL levels, sample sizes, and defect classifications.
What Is the AQL Chart?
The AQL chart comes from the ANSI ASQ Z1.4 standard and ISO 2859-1. It is a table that matches your batch size to a sample size and tells you the maximum number of defects allowed.
AQL stands for Acceptable Quality Limit. It is not zero defects. It is the worst quality level that is still acceptable for your product.
How to Read the AQL Chart in 3 Steps
Step 1: Find Your Lot Size
The AQL chart is split into rows by lot size (the total number of units in your order). Find your lot size in the first column.
| Lot Size Range | Sample Size Code | Sample Size |
|---|---|---|
| 2 to 8 | A | 2 |
| 9 to 15 | B | 3 |
| 16 to 25 | C | 5 |
| 26 to 50 | D | 8 |
| 51 to 90 | E | 13 |
| 91 to 150 | F | 20 |
| 151 to 280 | G | 32 |
| 281 to 500 | H | 50 |
| 501 to 1,200 | J | 80 |
| 1,201 to 10,000 | L | 200 |
| 10,001 to 35,000 | M | 315 |
| 35,001 to 150,000 | N | 500 |
Step 2: Choose Your AQL Level
The AQL level tells you how strict the inspection is. Common AQL levels are:
- AQL 0.65 — Very strict. Used for electronics, safety products, and critical components.
- AQL 1.0 — Strict. Used for most consumer electronics and appliances.
- AQL 2.5 — Normal. Used for general consumer goods, textiles, and toys.
- AQL 4.0 — Loose. Used for simple products like bags, basic tools, and packaging.
Step 3: Read the Accept and Reject Numbers
Once you have your sample size and AQL level, the chart gives you two numbers:
- Accept number (Ac): The maximum number of defects allowed. If defects are at or below this number, the batch passes.
- Reject number (Re): The defect count that causes a fail. If defects meet or exceed this number, the batch fails.
AQL Sampling Chart Example
You order 5,000 units of a consumer product with AQL 2.5.
- Lot size 5,000 → Sample size code L → Sample 200 units
- AQL 2.5 → Accept (Ac) = 10, Reject (Re) = 11
- Your inspector checks 200 units. If 10 or fewer have defects, the batch passes. If 11 or more have defects, it fails.
Common AQL Levels by Product Type
| Product Type | Recommended AQL | Reason |
|---|---|---|
| Electronics | 0.65 to 1.0 | High risk, complex products |
| Textiles and clothing | 2.5 | Standard for consumer goods |
| Toys and kids products | 1.0 to 2.5 | Higher safety standards |
| Hard goods and tools | 2.5 to 4.0 | Less critical defects |
| Packaging and bags | 4.0 | Simple products, fewer defect types |
Three Types of Defects in the AQL Chart
The AQL chart uses three defect categories:
- Critical defects: Unsafe or illegal. Zero tolerance. One critical defect fails the entire batch.
- Major defects: Will cause the product to fail in normal use. Examples: broken parts, wrong dimensions.
- Minor defects: Do not affect function but look bad. Examples: scratches, color variation, loose threads.
Most inspection reports apply AQL 0 for critical, AQL 2.5 for major, and AQL 4.0 for minor defects.
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Related Articles
- AQL Sampling Explained: How to Read the AQL Table and Choose Your Sample Size
- AQL Calculator: How to Calculate Sample Size and Acceptance Number for Product Inspection
- AQL Sampling Explained: How Many Products Should You Inspect?
Frequently asked questions
What Is the AQL Chart?
The AQL chart comes from the ANSI ASQ Z1.4 standard and ISO 2859-1. It is a table that matches your batch size to a sample size and tells you the maximum number of defects allowed.