AQL Inspection Manual

Dictionary
Acceptance Number. The acceptance number is the maximum number of defects or
defective units in the sample that will permit acceptance lot or batch.

AQL has two different definitions due to standard changes.

MIL-STD-105E, ISO 2859-1 (1999)

Acceptable Quality Level. The acceptable level (AQL) is defined as the maximum
percent defective (or the maximum number of defects per hundred units) that, for
purpose of sampling inspection, can be considered satisfactory as a process average.
The sampling plans most frequently used by the department of Defense are based on
the AQL.

ANSI/ASQC Z1.4-2003

Acceptance Quality Limit. The AQL is the quality level that is the worst tolerable
process average when a continuing series of lots is submitted for acceptance sampling.

The following note on the meaning of AQL was introduced with the ANSI/ASQ Z1.4-
2003 revision.

The concept of AQL only applies when an acceptance sampling scheme with rules for
switching between normal, tightened and reduced inspection and discontinuance of
sampling inspection is used. These rules are designed to encourage suppliers to have
process averages consistently better than the AQL. If suppliers fail to do so, there is a
high probability of being switched from normal inspection to tightened inspection where
lot acceptance becomes more difficult. Once on tightened inspection, unless corrective
action is taken to improve product quality, it is very likely that the rule requiring
discontinuance of sampling inspection will be invoked.

Although individual lots with quality as bad as the AQL can be accepted with fairly high
probability, the designation of an AQL does not suggest that this is necessarily a
desirable quality level. The AQL is a parameter of the sampling scheme and should not
be confused with a process average which describes the operating level of a
manufacturing process. It is expected that the product quality level will be less than the
AQL to avoid excessive non accepted lots.

The AQL values are defined as percent nonconforming or defects or nonconformities

per hundred units.
Defects and Defectives. A defect is any nonconformance of the unit of product with the
specified requirements. A defective is a unit of product which contains one or more
defects. Failure to meet requirements with respect to quality characteristics are usually
described in terms of defects or defectives.

Critical - A critical defect is on that judgment and experience indicate is likely to:

a. result in hazardous or unsafe conditions for individuals using, maintaining, or

depending upon the products; or
b. prevent performance of the tactical function of a major end item. A critical
defective is a unit of product that contains one or more critical defects.

Major - A major defect is one, other than critical, that is likely to result in failure, or to
reduce materially the usability of the unit of product for its intended purpose. A major
defective is a unit of product that contains one or more major defects.

Minor - A minor defect is one that is not likely to reduce materially the usability of the
unit of product for its intended purpose, or is a departure from established standards
having little bearing on the effective use or operation of the unit of product. A Minor
defective is a unit of product that contains one or more defects.

Double Sampling Plan. A double sampling plan involves sampling inspection in which
the inspection of the first sample to a decision to accept, to reject or to take a second
sample. The inspection of a second sample, when required, lead to a decision to accept
or reject.

Drawing of Samples. Basic to sampling inspection is the assurance that the sample
selected from a quantity of units represents the quality of that quantity of units. Hence,
the procedure used to select units from a lot must be such that it assures a sample free
of bias.

Expression of Nonconformance. The extent of nonconformance of product shall be

expressed either in terms of percent defective or in terms of defects per hundred units
(DHU).

Defects per Hundred Units. The number of defects per hundred units of any given
quantity units of product is one hundred times the number of defects contained therein
(one or more defects being possible in any unit of product) divided by the total number
of units of product, i.e.:

number of defectives x 100

Defects per hundred units =
number of units inspected
Inspection. Inspection is the process of measuring, examining, testing, or otherwise
comparing the unit of product with the requirements.

Inspection by Attribute. Inspection by attributes is inspection where by either the unit

of product is classified simply as defective or non-defective, or the number of defects in
the unit of product is counted, with respect to a given requirement or set of
requirements.

Inspection Levels. The standards provides for three general inspection levels and four
special inspection levels. These seven levels permit the user to balance the cost of
inspection against the amount of protection required.

Lot or Batch. The term lot or batch shall mean "inspection lot" or "inspection batch" i.e.,
a collection of units of product from which a sample is to drawn and inspected to
determine conformance with the acceptance criteria, any may differ from a collection of
units designated as a lot or batch for other purposes (e.g., production, shipment, etc.).

Nonconformance. Nonconformance may be defined as the failure of a unit of product

to conform to specified requirements for any stated quality characteristic. The extent of
nonconformance of product to the required quality characteristics shall be expressed
either in terms of percent defective or in terms of defects per hundred units (DHU).

Normal Inspection. Normal inspection is that which is used where there is no evidence
that the quality of product being submitted is better or poorer than the specified quality
level.

Percent Defective. The percent defective of any given quantity of units of product is
one hundred times the number of defective units of product contained therein divided by
the total number of units of product, i.e.: Percent defective = number of defectives
x100 / number of units inspected

Reduced Inspection. Reduced inspection under a sampling plan uses the same quality
level as for normal inspection, but requires a smaller sample for inspection.

Rejection Number. The rejection number is the minimum number of defects or

defective units in the sample that will cause rejection of the lot represented by the
sample.

Representative Sampling. When appropriate, the number of units in the sample shall
be selected in proportion to the size of sub-lots or sub-batches, or parts or the lot or
batch, identified by some rational criterion. When representative sampling is used, the
units from each part of the lot or batch shall be selected at random.

Resubmitted Lots or Batches. Lots or batches found unacceptable shall be

resubmitted for reinspection only after all units are re-examined or retested and all
defective units are removed or defects corrected. The responsible authority shall
determine whether normal or tightened inspection shall be used and whether
reinspection shall include all types or classes of defects or only the particular types or
classes of defects which caused initial rejection.

Sample. A sample consists of one or more units of product drawn from a lot or batch,
the units of the sample being selected at random without regard to their quality. The
number of product in the sample is the sample size.

Sampling Plans. A lot sampling plan is a statement of the sample size or sizes to be
used and the associated acceptance and rejection numbers.

Single Sample Plan. A single sampling plan is a type of sampling plan by which the
results of a single sample from an inspection lot are conclusive in determining
acceptability. The number of sample units inspected shall be equal to the sample size
given by the plan.

Severity of Inspection. The severity of inspection concerns the total amount, kind and
extent of inspection specified by the quality assurance provisions established for the
unit of product, or as dictated by quality history.

Unit of Production. The unit of product is the thing inspected in order to determine its
classification as defective or non-defective or to count the number of defects. It may be
a single article, a pair, a set, a length, an area, an operation, a volume, a component of
an end product, or the end product itself. The unit of product may or may not be the
same as the unit of purchase, supply, production, or shipment.

Tightened Inspection. Tightened inspection under a sampling procedure plan uses the
quality level as for normal inspection, but requires more stringent acceptance criteria.