Free AQL Calculator for Garment Inspection
Welcome to the most comprehensive AQL Calculator for the textile and garment industry. This tool simplifies the complex ISO 2859-1 (ANSI/ASQ Z1.4) tables into an instant result.
Whether you are a merchandiser calculating Garment Costing or a quality inspector performing a Final Random Inspection, accuracy is key to avoiding shipment rejections.
How to Use This AQL Calculator
Using this garment inspection calculator is simple. Follow these steps to get a complete inspection plan:
1. Enter Order Details
- Order Quantity: Input the total number of pieces in the shipment.
- Total Cartons: Input the total number of boxes. The calculator applies the standard Square Root Rule to determine logistics.
2. Select Inspection Level
- General Level II: The industry standard for cosmetic/visual checks.
- Special Levels (S-1 to S-4): Used for destructive testing (e.g., zipper pull tests, GSM check) where sample sizes must be small.
3. Select AQL Limits
- Critical (Default 0): Safety hazards (needles, mold).
- Major (Default 2.5): Functional defects (holes, open seams).
- Minor (Default 4.0): Cosmetic defects (threads, shading).
Standard AQL Reference Charts (ISO 2859-1)
While our calculator above does the math instantly, you can reference the official manual tables below.
Table 1: Sample Size Code Letters
Find your Lot Size (Order Qty) and Inspection Level to determine your Code Letter.
| Lot Size | Special Inspection Levels | General Inspection Levels | |||||
|---|---|---|---|---|---|---|---|
| S-1 | S-2 | S-3 | S-4 | I | II | III | |
| 2 to 8 | A | A | A | A | A | A | B |
| 9 to 15 | A | A | A | A | A | B | C |
| 16 to 25 | A | A | B | B | B | C | D |
| 26 to 50 | A | B | B | C | C | D | E |
| 51 to 90 | B | B | C | C | C | E | F |
| 91 to 150 | B | B | C | D | D | F | G |
| 151 to 280 | B | C | D | E | E | G | H |
| 281 to 500 | B | C | D | E | F | H | J |
| 501 to 1,200 | C | C | E | F | G | J | K |
| 1,201 to 3,200 | C | D | E | G | H | K | L |
| 3,201 to 10,000 | C | D | F | G | J | L | M |
| 10,001 to 35,000 | C | D | F | H | K | M | N |
| 35,001 to 150,000 | D | E | G | J | L | N | P |
| 150,001 to 500,000 | D | E | G | J | M | P | Q |
| 500,001 and over | D | E | H | K | N | Q | R |
Table 2: Single Sampling Plan (Normal Inspection)
Use your Code Letter to find the Sample Size and the Accept/Reject limits for standard AQLs.
| Code | Sample Size | AQL 1.5 (Ac / Re) |
AQL 2.5 (Ac / Re) |
AQL 4.0 (Ac / Re) |
|---|---|---|---|---|
| A | 2 | 0 / 1 | 0 / 1 | 0 / 1 |
| B | 3 | 0 / 1 | 0 / 1 | 0 / 1 |
| C | 5 | 0 / 1 | 0 / 1 | 0 / 1 |
| D | 8 | 0 / 1 | 0 / 1 | 1 / 2 |
| E | 13 | 0 / 1 | 1 / 2 | 1 / 2 |
| F | 20 | 1 / 2 | 1 / 2 | 2 / 3 |
| G | 32 | 1 / 2 | 2 / 3 | 3 / 4 |
| H | 50 | 2 / 3 | 3 / 4 | 5 / 6 |
| J | 80 | 3 / 4 | 5 / 6 | 7 / 8 |
| K | 125 | 5 / 6 | 7 / 8 | 10 / 11 |
| L | 200 | 7 / 8 | 10 / 11 | 14 / 15 |
| M | 315 | 10 / 11 | 14 / 15 | 21 / 22 |
| N | 500 | 14 / 15 | 21 / 22 | 21 / 22 |
Advanced Logistics: Cartons, Sizes, and POs
AQL tells you how many to check, but logistics tell you where to get them and how to plan the shipment.
1. The Carton Square Root Rule
You cannot open just one box. You must select cartons randomly from the front, middle, and back of the pile. Once you know your total carton count, you should also calculate the volume using our CBM Calculator to ensure the goods fit in your container.
2. Proportional Sampling (Sizes & Colors)
Your sample must match the order breakdown. If your order is 50% Black and 50% White, your sample of 200 pcs must also be 100 Black and 100 White. Never inspect just one color or one size.
Essential Tools for Garment Professionals
Quality control is just one part of the manufacturing process. Use these other free tools to optimize your production and merchandising:
-
Fabric Consumption Calculator
Before production begins, calculate exactly how much fabric you need per dozen garments to avoid shortages or wastage. -
Garment CM & Total Costing Calculator
Determine your FOB price accurately by factoring in fabric, trims, making charges, and commercial costs. -
Line Efficiency Calculator
Analyze your factory’s performance. Compare your targets vs. actual output to improve SMV and production speed. -
CBM Calculator (Container Optimizer)
Calculate the Cubic Meter volume of your cartons to plan shipping logistics (20ft vs 40ft containers).
Frequently Asked Questions (FAQ)
Q: What happens if the shipment fails the AQL inspection?
A: If the number of defects exceeds the “Reject” number, the shipment is rejected. The factory must then “re-work” the goods (repair defects, clean stains, trim threads) by checking 100% of the quantity. After re-working, a Re-Inspection is booked, usually at the factory’s expense.
Q: Why is “General Level II” the default setting?
A: Level II is the global standard for the apparel industry. It provides the best balance between risk and cost. Level I is too loose (high risk of bad quality slipping through), and Level III takes too long (too expensive) for standard orders. Only change this if your buyer specifically requests it.
Q: What is the difference between AQL 2.5 and AQL 1.5?
A: AQL 2.5 is the standard for mass-market retailers (e.g., H&M, GAP, Zara). AQL 1.5 is stricter and typically used for high-end or luxury brands where very few defects are tolerated. AQL 4.0 is used for promotional items or lower-tier goods.