What AQL means
AQL (acceptable quality limit) is a sampling method. Instead of checking every piece, an inspector checks a statistically chosen sample from the finished lot. The lot passes if the number of defects found is within the limit for that sample size.
Major, minor and critical defects
Major defects affect saleability (holes, open seams, wrong measurements); minor defects are small cosmetic issues; critical defects affect safety. Many apparel buyers use AQL 2.5 for major and 4.0 for minor defects, with zero tolerance for critical.
What gets checked
Workmanship, measurements against the spec, colour and shade, labels and packing, and any function such as zips and buttons.
Inspection is the last line, not the first
Good quality comes from fabric checks, inline inspection on the sewing line and clear standards, so final inspection confirms rather than discovers.