In short: A pre-shipment inspection checks a random sample of finished, packed goods against your approved sample before the shipment leaves. The sample size and the number of defects allowed follow the AQL standard (ISO 2859-1). Common levels for fashion products are AQL 2.5 for major and 4.0 for minor defects.
What is a pre-shipment inspection?
When production is at least 80% finished and packed, an inspector visits the factory and picks cartons at random. The goods are checked against the approved sample and the order details. The result is a written report with photos and a clear outcome: passed, failed or pending your decision.
How AQL sampling works
AQL stands for Acceptance Quality Limit. Instead of checking every piece, the inspector checks a statistically defined sample. The order size determines how many pieces are checked, and the chosen AQL level determines how many defects are accepted. Example: for an order of 3,000 pieces at general inspection level II, 125 pieces are checked.
Critical, major and minor defects
- Critical: unsafe or illegal, for example a sharp object or a missing mandatory label. Usually zero tolerance.
- Major: the customer would likely return the product, for example a broken zip, wrong size or visible stain.
- Minor: a small deviation that does not affect use, for example a loose thread end.
What is checked
- Quantity and packing against the packing list
- Measurements against the size chart and tolerances
- Workmanship: seams, stitching, edges, symmetry
- Colour and material against the approved sample
- Function: zips, buttons, buckles, snaps
- Labels, hangtags, barcodes and carton marking
If the inspection fails
A failed inspection is not the end — it is the reason to inspect. The usual next step is sorting and rework at the factory, followed by a re-inspection. Agree upfront who pays for a re-inspection; often it is the supplier.
In-line inspection: catching problems earlier
For new products or large orders an in-line inspection during production is worth it. It finds systematic errors while there is still time to correct them, rather than at the end.
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