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DeutschQuality control is not a formality carried out once production ends; it is a series of checkpoints built into the process. The cost of a defect multiplies with the stage at which it is caught: found in a sample it costs one piece, found after shipping it costs the whole run and your brand's standing.
What does AQL mean? AQL (Acceptable Quality Limit) is a method of judging a production lot from a statistical sample rather than inspecting every piece. A set number of units is drawn at random, defects are counted, and if the count exceeds the threshold agreed in advance, the lot is rejected.
Where checks happen
Quality is not checked at a single point but at several stages of production. A defect caught at each stage costs far more at the next.
How defects are classified
Not every defect carries the same weight. The industry-standard split is threefold:
Critical defect: a fault that makes the product unusable or unsafe — a needle left inside a garment, for example. There is no tolerance for critical defects.
Major defect: a fault the customer will notice and return the item for. A stain in a visible place, a skipped seam, a wrong measurement, a misplaced print.
Minor defect: a deviation from standard that does not prevent sale, such as a short loose thread where it will not be seen.
AQL thresholds are set separately for each class; for critical defects the threshold is zero.
How AQL works
Inspecting every piece in a thousand-unit lot is impractical, and the cost of doing so lands on the product. That is why AQL exists.
A number of units determined by the lot size is drawn at random — from different cartons, not off the top of one box. Each selected piece is examined and defects are counted and classified. If the count exceeds the accept number agreed for that class, the lot is rejected; if not, it is accepted.
What matters is that the AQL level is agreed in writing before the order. A quality standard discussed afterwards is always open to dispute.
What you should ask for
Pinning down the quality side is in your hands when working with a manufacturer. Ask for these at the order stage:
How we work
Our reference in production is the sample you approved. A copy of that approved sample stays with us and production is checked against it.
Checks are not confined to one stage; they run from fabric intake through to shipping. Goods are inspected before despatch, and we send you the inspection photographs on request. If you would rather use an independent inspection company, we are open to them coming to the factory.
When something goes wrong, we tell you. Shipping quietly and waiting for your customer to find it does not pay off for anyone, even in the short term.
Frequently Asked Questions
Do you provide a quality control report?
Yes, on request we share the pre-shipment inspection results and photographs. Which checks will be carried out is agreed with you at the order stage.
Can I use an independent inspection company?
Yes. We are open to an inspection company of your choosing attending the factory for pre-shipment checks, and we help with scheduling and access.
Does a colour difference count as a defect?
Slight shade variation between dye lots is normal in textiles and is not in itself a defect. If the difference exceeds the acceptable range against the approved sample, it is. That is why colour approval on a physical sample matters.
What happens if defective goods are produced?
Where a notice is justified we agree on replacement, rectification or a price reduction. The process and timescales are set out on our Terms and Conditions page.