AQL Sampling Plans for Electronics Inspection
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AQL (Acceptable Quality Limit) is the statistical basis for nearly every pre-shipment inspection of electronics out of China, defined by ANSI/ASQ Z1.4 (the successor to MIL-STD-105E). It sets how many units to pull from a lot and how many defects are allowed before the lot fails. For consumer electronics we typically run General Inspection Level II with AQL 2.5 for major defects and 4.0 for minor — a 1,000-unit lot then means sampling 80 pieces.
When you actually source on AQL terms, the numbers you choose are negotiable contract terms, not fixed rules — tightening from 2.5 to 1.0 means a stricter pass bar and usually a higher inspection cost. The common pitfall is accepting a supplier's vague 'we inspect everything' claim; we specify the inspection level, AQL per defect class, and the defect classification list in writing before booking the inspection.
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FAQ
What AQL should I use for consumer electronics?
A common starting point is AQL 0 critical / 2.5 major / 4.0 minor at General Inspection Level II. For higher-reliability or branded goods, buyers tighten the major limit to 1.5 or 1.0.
How many units get inspected under AQL?
It depends on lot size and inspection level, not a fixed percentage. Under Level II, a 1,000-unit lot samples 80 pieces; a 5,000-unit lot samples 200. The Z1.4 tables map lot size to sample size.
What happens if a lot fails AQL inspection?
You can reject the lot, require 100% sorting and rework before re-inspection, or renegotiate, depending on the defect type. Critical-class defects (safety) usually mean an automatic hold regardless of the AQL count.
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