AQL 2.5 Inspection for Activewear: A Buyer’s Guide
AQL 2.5 appears on almost every factory’s website, but it is often misunderstood. This guide explains what it means, how many garments are checked, how defects are classified and what to agree before production, using the reference values on our quality control page.
- AQL is a sampling plan, not a guaranteed defect rate.
- It sets two numbers: how many garments to inspect and how many nonconforming garments are acceptable.
- Defects are classified as critical, major or minor, and assessed separately.
- The approved sample and specification are the inspection reference.
- Final inspection is the last step, not the whole of quality control.
What is AQL?
AQL stands for Acceptance Quality Limit. Checking every garment in a bulk order is slow and costly, so inspectors take a random sample from the lot and decide whether to accept it based on what they find. An AQL table tells them how large the sample should be and how many nonconforming garments the plan allows.
AQL 2.5 is widely used for apparel. The reference values below use General Inspection Level II with normal single sampling.
What AQL 2.5 does not mean
The most common misunderstanding is that AQL 2.5 means “2.5% of the order can be defective”. It does not. AQL 2.5 indexes a sampling plan. It is not a guaranteed shipment defect rate, and it is not permission to supply defective goods. The agreed standard, defect classification, counting method and buyer inspection plan govern the final decision.
AQL 2.5 sample sizes for activewear orders
| Lot size (pcs) | Sample (pcs) | Accept (Ac) | Reject (Re) |
|---|---|---|---|
| 151–280 | 32 | 2 | 3 |
| 281–500 | 50 | 3 | 4 |
| 501–1,200 | 80 | 5 | 6 |
| 1,201–3,200 | 125 | 7 | 8 |
| 3,201–10,000 | 200 | 10 | 11 |
Reference values for normal single sampling at General Inspection Level II, for one defect class, based on ANSI/ASQ Z1.4 published tables. This summary is not a substitute for the agreed full standard.
A worked example: 500 leggings
For a lot of 500 pieces, the inspector takes 50 randomly selected pieces and checks them against the approved specification. For one defect class:
- If 3 or fewer pieces are nonconforming (Ac 3), the lot passes for that class.
- If 4 or more pieces are nonconforming (Re 4), the lot fails for that class.
Each nonconforming garment is counted once within the assessed class, rather than adding every individual defect as a separate garment. Other defect classes, critical issues and buyer requirements are assessed separately.
Critical, major and minor defects
Defect classes should be agreed before bulk production. The examples below are typical for activewear; your own inspection plan decides how each finding is classified.
| Class | Meaning | Activewear examples |
|---|---|---|
| Critical | Safety, compliance or serious use issues, assessed separately from the AQL reference | A finding that could harm the wearer or break a compliance rule |
| Major | Can materially affect use, fit, appearance or saleability | Measurements outside tolerance, open seams, wrong size label, clear color differences |
| Minor | Smaller workmanship issues that do not materially affect use | A short loose thread or a small stitching irregularity |
What gets checked on activewear
These are the main areas. Our quality control checklist explains how to check each one.
- Measurements: key points against the agreed tolerances, measured by the agreed method.
- Workmanship: seams, waistbands, elastics, edges and finishing.
- Fabric and appearance: visible defects, marks and fabric condition.
- Color: against the approved reference, and across the pieces of matching sets.
- Function you have agreed: for example stretch, or opacity in a squat; see our squat-proof guide.
- Branding and packing: logos, labels, folding, polybags, quantities and carton information.
AQL is the last step, not the only step
Final sampling can only find problems once the goods are finished. That is why our checks run through production:
- IQC, incoming materials: bulk fabric or yarn, color lots and trims before production release.
- IPC, first production pieces: checked against the approved product before bulk continues.
- IPQC, in-process checks: construction, measurements, appearance and visible defects during production.
- FQC, finished garments: measurements, appearance, color and workmanship after finishing.
- OQC, shipment checks: final sampling results, labels, packing, quantities and cartons before release.
Cut & Sew and seamless checks
The route changes the working checkpoints. Cut & Sew checks focus on fabric and trims, cutting and panel alignment, seam construction, measurements and finishing. Seamless checks focus on yarn and color lots, program and knit-structure accuracy, dimensions, stretch and visible defects. Compare the two routes.
What to agree before production
- The approved sample and tech pack version.
- Measurements, tolerances and how each point is measured.
- Approved fabric, trims and color references.
- Workmanship requirements and any function tests.
- Labels, folding and packing instructions.
- Your inspection plan: defect classes, counting method, sampling settings and acceptance rules.
- Who will inspect, and what happens if a lot fails, such as sorting and re-inspection.
The more of this that sits in your tech pack, the easier inspection becomes. If you plan to use a third-party inspector, include that in the plan too. Your approved sample is the reference for everything above, so take care at the sampling stage.
Common AQL mistakes
- Treating AQL 2.5 as an allowed defect rate.
- Agreeing on “AQL 2.5” without defining defect classes.
- No measurement tolerances, so findings cannot be judged.
- Inspecting against a photo instead of the approved sample.
- Relying on final inspection alone.
Choosing a factory? See how quality fits into our guide to vetting an activewear manufacturer, and find the full reference on our quality control page.
Frequently asked questions
What does AQL 2.5 mean in garment inspection?
AQL 2.5 refers to a sampling plan. It sets how many garments are inspected from a lot and how many nonconforming garments can be found before the lot is rejected for that defect class. It is not a guaranteed defect rate.
Does AQL 2.5 mean 2.5% of my order can be defective?
No. AQL 2.5 indexes a sampling plan; it is not a promise about the shipment’s defect rate or permission to supply 2.5% defective goods. The agreed inspection plan governs the final decision.
How many garments are inspected for a 500-piece order?
At AQL 2.5, General Inspection Level II, normal single sampling, a lot of 281–500 pieces uses a sample of 50 pieces, with an acceptance number of 3 and a rejection number of 4 for the assessed defect class.
What is the difference between critical, major and minor defects?
Critical findings relate to safety, compliance or serious use issues and are assessed separately. Major findings can materially affect use, fit, appearance or saleability. Minor findings are smaller workmanship issues that do not materially affect use.
What is checked in an activewear inspection?
Inspection follows the approved sample and specification: measurements, appearance, color, workmanship, labels, packing, quantities and carton information. Buyers can also agree product-specific checks, such as opacity or stretch.
Is AQL inspection enough on its own?
No. Final sampling only looks at finished goods. Good quality control starts earlier, with checks on incoming materials, first production pieces and in-process work.
Have inspection requirements?
Tell us about your product, quantity and any inspection plan you work to. We review the details and reply with a quote within 24 hours. Only your work email is required.
- A tech packShare technical drawings, measurements and material requirements.
- A reference productShare a photo, product link or sample, with the details you want to develop.
- An early ideaDescribe the category, intended activity and wearing experience.