Definition:

A statistical measurement of the

maximum number of defective goods considered
acceptable in a particular sample size.
 Defects
Visual defects are categorized as Critical, Major and
Minor depending on the intensity and area of the
defects.
 Types of defects considered in AQL
Critical Defects: are those that render the product
unsafe or hazardous for the end user or that
contravene mandatory regulations.
Example:
Presence of insects, broken needle in the garment, etc.
Types of defects considered in AQL
Major defects: can result in the product’s failure,
reducing marketability, usability.
Example:
Broken Stitch, Stain, etc.
Types of defects considered in AQL
Minor Defects: do not affect products marketability
or usability but represents workmanship defects that
make the product fall short of defined quality
standard.
Example:
Minor stain, Puckering in small scale, etc.
List of Defects and their Categories (Fabric)
Sl# Name of Defects Critical Major Minor

01 Presence of Broken Needle x

02 Presence of Insects in the Garments x

03 Hole (any Size) x

04 Needle Mark (Knitting) x x

05 Sinker Mark x x

06 Fly x x

07 Starting Mark x x

08 Patta /Barre Mark x

09 Lycra Out x
List of Defects and their Categories (Fabric)
Sl# Name of Defects Critical Major Minor

10 Warp Missing x

11 Slub x x

12 Thick Yarn/Thin Yarn x

13 Knot x x

14 End Out x

15 Crease Mark x x

16 Stop Mark x x

17 Missing Yarn x

18 Patch Mark x x
List of Defects and their Categories (Fabric)
Sl# Name of Defects Critical Major Minor

19 Yarn Contamination x x
List of Defects and their Categories (Sewing)
Sl# Name of Defects Critical Major Minor

1 Broken Stitch x

2 Puckering x x

3 Poor Neck Shape x x

4 Mismatch Stripe/Check x x

5 Uncut Thread x

6 Skip Stitch x

7 Size Mistake x

8 Label Mistake x

9 Back Tape run off Stitch x

List of Defects and their Categories (Sewing)
Sl# Name of Defects Critical Major Minor

10 Uneven Body Hem x x

11 Wrong placed Button/Up-Down x x

12 Button Missing x

13 Incomplete Button Stitch x

14 Shade Variation between Parts x x

15 Poor Shaped Pocket x

16 Raw Edge x

17 Uneven Width of Placket x x

18 Slanted Pocket x x
List of Defects and their Categories (Sewing)
Sl# Name of Defects Critical Major Minor

19 Slanted Zipper attachment x

20 Chalk mark x
21 Open Seam x
22 Thread not DTM x
23 Poor Neck Shape x
24 Uneven Sleeve Length x
25 Loose Stitch x x
26 Blind Stitch Visible x
27 Skipped Stitch x
List of Defects and their Categories (Sewing)
Sl# Name of Defects Critical Major Minor

8 Uneven Stitch x x
29 Button Hole Damaged x
30 Incomplete Button Hole Stitch x
31 Pleat x x
32 Placing Mark x
List of Defects and their Categories (Finishing)
Sl# Name of Defects Critical Major Minor

01 Dirty Spot x x
02 Oil Spot x x
03 Hang Tag Missing x
04 Wrong Hang Tag x
05 Iron Mark x x
06 Poor Iron x
07 Gum Mark of Interlining x x
08 Loose Thread x
List of Defects and their Categories (Miscellaneous)
Sl# Name of Defects Critical Major Minor

01 Printing Spot x x

02 Misplaced Print x x

03 Slanted Print x x

04 Incomplete Embroidery x

05 Misplaced Embroidery x x

06 Presence of insects x
07 Presence of broken needle x
08 Sharp edge of Rivet x
 The 3 general inspection levels
Level I
Has this supplier passed most previous inspections? Do
you feel confident in their products quality? Instead of
doing no quality control, buyers can check less samples by
opting for a level-I inspection.
However, settling on this level by default, in order to spend
less time/money on inspections, is very risky. The
likelihood of finding quality problems is lower than
generally recommended.
Level II
It is the most widely used inspection level, to be used by
default.
 The 3 general inspection levels

Level III
If a supplier recently had quality problems, this level is
appropriate. More samples are inspected, and a batch of
products will (most probably) be rejected if it is below
the quality criteria defined by the buyer.
Some buyers prefer level-III inspections for high-value
products. It can also be interesting for small quantities,
where the inspection would take only one day whatever
the level chosen.
AQL Chart
Checking areas in Inspection
Material Conformity
Style Conformity
Quantity Conformity
Workmanship (AQL)*
Measurement
Shade Conformity
Packing and Packaging Conformity
Selection of garment and carton
Buyers instruct about the required AQL
Usually Major – 2.5
Usually Minor – 4.0
Usually Critical – zero tolerance
Cartons should be randomly selected
Numbers of carton to be selected = √n
All color and size should have the proportionate
representation on the garments to be inspected
Measurement should cover all color and size that are
to be inspected