Before any order ships to you, it passes through a final quality inspection. This walkthrough explains what we check, how defects are graded, and what AQL means for your order.
What AQL Is
AQL (Acceptable Quality Limit) is the industry-standard sampling method for inspecting finished goods.
- Instead of checking 100% of pieces, a random sample is drawn based on the order size
- The sample size and pass/fail cutoffs follow standard AQL tables (commonly AQL 2.5 for critical-to-quality items)
- AQL doesn’t mean defects are acceptable — it means the defect count must stay within an agreed tolerance at the sampled rate
What Gets Checked
For most promotional goods, we inspect:
- Appearance: color match to approved sample, print/stitch quality, finish and surface defects
- Dimensions: size, capacity and tolerances against the spec
- Function: zippers, lids, straps, closures, moving parts work correctly
- Print: logo placement, registration, and durability (peel / wash / scratch tests where relevant)
- Cleanliness: the item is clean, free of stains, oil or foreign matter
How Defects Are Graded
Each defect is classified by severity:
- Critical: a safety issue or something that makes the product unfit for use
- Major: visible defect or functional problem that would likely be rejected by an end customer
- Minor: defect that doesn’t affect function or normal appearance (e.g. a slight thread end)
The number of major and minor defects is compared against the AQL table. If the sample exceeds the limit, the whole lot is re-inspected or reworked before re-submitting.
What Happens If a Lot Fails
A failing lot doesn’t ship as-is:
- The factory corrects the defects (repair or rework)
- 100% inspection may be required on the affected items
- The lot is re-sampled and inspected again until it passes
- Only a passing lot gets packed for shipment
Watch the Walkthrough
Video coming soon to this page. Want to see our quality control setup up close, or discuss AQL levels for your order? Contact us and we’ll walk you through the details.