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How to select AQL and inspection level
QUALITY DIGEST| TUE, 09/04/2001
I want to now t!e p"inciple o# selectin$ AQL and inspection level w!en %sin$ t!e sa&plin$ p"oced%"es and
ta'les( )o" e*a&ple, w!en I %se +IL-T.10E, !ow to decide w!en I s!o%ld %se I, II o" -2, -4
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Comments12/14/2004 132 5+ 6 QUALITY DIGESTblairhogg 12/14/2004
T"7 so&et!in$ lie t!is -elect at "ando& seve"al sa&ples o# di##e"ent wei$!ts, %p to t!e &a*i&%& wei$!t to 'e
&eas%"ed( Identi#7 t!ese sa&ples 81,2,,4:( La'el t!ese a,',c,d, eepin$ t"ac o# w!ic! sa&ple 8ad: is w!ic!
sa&ple 814:, t!en !ave so&eone wei$! t!e& and "eco"d t!e wei$!ts( ;!an$e t!e sa&ple id?> 'eca%se so&e te*t 'oo o" I-
Q%alit7 -tanda"d s%$$ests it(
Fo!n @"%&an
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12/11/2004 1329 5+ 6 QUALITY DIGESTbobdoering 12/11/2004
a$e >?> is a ve"7 powe"#%l tool it collects ALL va"iation and ana7Ges t!e 'etween 8app"aise" va"iation: and
wit!in 8eB%ip&ent va"iation: va"iation( @7 %sin$ t!e va"io%s containe"s o# vast va"iation in wei$!t, t!e tool will
s!ow 7o% !ave t!is va"iation and will liel7 &as an7 ot!e" va"iation #"o& 7o%" $a$in$ s7ste&( =o% @etween
sa&ple va"iation 8A: will 'e p"ett7 'i$(
ene"all7, t!is va"iation o# t!e &eas%"e&ent s7ste& is t!en co&pa"ed to t!e speci#ication 8o" cont"ol li&its, i#
%sed: to dete"&ine i# it p"ovides adeB%ate "esol%tion o" answe"s t!e B%estion !ow do 7o% now it is t!e "i$!t
$a$e #o" t!e Do'( I# w!at 7o% a"e &eas%"in$ !as no speci#ication, t!en w!at is it 7o% a"e t"7in$ to s!ow wit! t!e
$a$e >?> In o"de" to answe" t!is B%estion, we p"o'a'l7 need to $et a 'ette" idea w!at t!e scena"io is( C!at is
t!e speci#ication t!e a&o%nt o# &ate"ial t!at is "eB%i"ed in t!e p"ocess and its tole"ance How do t!e containe"s
"elate to t!e speci#ication JK a"e seve"al %sed #o" t!e add to t!e p"ocess
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T!e one t!in$ I can ass%"e 7o% t!at 7o% s!o%ld T do is %se one ope"ato"M =o% s!o%ld !ave t!e va"iation o#
&eas%"e&ent sills "ep"esented in a a$e >?> #"o& ce"ti#ied t"ainee to e*pe"ienced ope"ato"( T!e onl7 ti&e
t!is tool s!o%ld 'e %sed wit! one ope"ato" is i# 7o% a"e t"7in$ to dete"&ine t!e 'etween va"iation o# seve"al
$a$es, s%c! as 1 ope"ato", $a$es, 10 pa"ts instead o# 1 $a$e, ope"ato"s, 10 pa"ts( T!is is anal7tical p"ocess
t!at is "a"el7 %sed co""ectl7, !oweve"(
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AQL Sampling
-ea"c!
Quality professionals use AQL sampling to determine the acceptance or rejection ofinspection material. Inspection material can be raw goods, purchased parts, inprocess
production, final goods and services, pre and post shipment parts, etc. Inspectorsdepend on AQL plans to determine the amount of parts to inspect.
AQL stands for Acceptable Quality Level. AQL is the poorest level of uality for theprocess that you would consider acceptable.
!tages of AQL !ampling
". #irst select the appropriate industrial sampling plan.
$. %etermine the AQL &'. %ecide the sampling plans parameters
(. )stablish the sample si*e, accept and reject criteria
+. andomly select the parts.
-. Inspect each part for the given features/
0. Accept or eject the remaining parts.
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Snap Sampling Plans!
%o you...
Inspect parts, items, material1
2eed an AQL sampling method that supports your inspection
activities1
3ant to uic4ly apply the correct sampling method based on
your production methods1
3ant to swiftly determine the correct sample si*e, accept and
reject criteria for your inspection1
5hin4 statistical sampling plans are difficult, confusing or
complicated1
2eed to chec4 your company6s sampling plans for the correct
application1
7a4e up your own sampling plans1
2eed to learn about a specific sampling plan because of your
customer reuirements1
3ant to improve your Quality !ystems1
If you answer yes to any of the above uestions then you need SnapSampling Plans!
Videos and pictures of Snap Sampling Plans!
7any companies use the wrong inspection AQL sampling plan becausemanagers, engineers, supervisors and inspectors have not been trainedin statistical sampling. 8ecause of this, they may create their owndeficient sampling plan. 9r they may use a 4nown industry standardplan without fully understanding that standard:s purpose or methods.
3hen this occurs, they put their business and their customers at ris4. Inaddition they waste valuable inspection time and inspection cost. %on6t
let this happen to your business.
Snap Sampling Plans!software combines all the 4ey industry standard
attribute sampling plans into one place. 8ecause there are over ";,;;;
sampling possibilities, you need this software to eliminate the confusion.!nap !ampling
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Selecting the Sampling Plan.
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#ind your inspection criteria on 5able %. >hanging parameters is very time consuming.
Snap Sampling Plans!software fiCes this.
Establish the Sample Size, Accept and Reject Criteria
5he main reason that the authors wrote each plan was to determine the sample si*e,
accept and reject criteria. After finding this you are done with the standards until theneCt inspection.
5he sample si*e number tells you how many parts to pull from the lot.
5he accept number tells you the maCimum allow number of rejects within that sample toaccept the lot.
5he reject number tells you the minimum number of defects within the sample to reject
the lot.
Randml Select the Parts
!elect the parts randomly from the lot is critical to ma4ing a sound decision on the lot. Ifyou pull the parts off the top of the pile for the inspection sample, this is not randominspection. In this case you are pulling parts from one moment of production time andthat moment does not represent the entire production. andom means that the samplecomes from an un4nown origin. 5here are many tools that generate random numbers.7any calculators have this built in feature.
"nspect Each Part
After you select the inspection sample you then inspect the parts. As you inspect the
parts, you separate the good parts from the bad parts.
Dou record the number of good parts and the number of rejects.
Dou may be inspecting multiple features or characteristics on the parts. %epending on thefeature importance, you may have different AQLs or Inspection parameters for eachfeature. 5his is difficult to master if you are relying on reviewing the industry standard
for each feature. If you:re doing this, try using Snap Sampling Plans!which ma4es multi@feature inspection easier.
Accept r Reject the Remaining Parts
8ased on your accept E reject number and the end results from the sample inspection,you decide whether or not to accept the material.
If the number of defects is less then or eual to the accept number you accept the parts.7ove the parts to the neCt step.
If the number of defects is greater or eual to the reject number you reject the parts.
!egregate the lot and issue corrective action.
http://www.quality-assurance-solutions.com/Snap-Sampling-Plans.htmlhttp://www.quality-assurance-solutions.com/Snap-Sampling-Plans.htmlhttp://www.quality-assurance-solutions.com/Snap-Sampling-Plans.htmlhttp://www.quality-assurance-solutions.com/Snap-Sampling-Plans.html -
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After reviewing this page on AQL sampling plans see this for more info on the sample
si*e calculator
The AQL Tables, Different Inspection Levels, and theSampling Plan Selection Process
http://www.quality-assurance-solutions.com/sample-size-calculator.htmlhttp://www.quality-assurance-solutions.com/sample-size-calculator.htmlhttp://www.quality-assurance-solutions.com/sample-size-calculator.htmlhttp://www.quality-assurance-solutions.com/sample-size-calculator.html -
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t chse
rect
l
tin Le&el '
&el...(
somebodylp me out
is main
onF)#$
se the
ct eneral
ctin
' AQL
and $hat
reliabilit
me()
many
tions by
al
tion Level
QL $.+.
nowing
is standard
monly
t me if I
ong. AQL
eans that
accept a
rate of
which
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ods are
fect.
y choosing
al
tion Level
ans doing a
e
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sult
red with
L table will
mine
on orance of the
3hat is
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ability of
cision
on these
cs1
ay, I do
structive
n a batch
@$B;pcs. I
to accept
vel ".;. 7y
sults
be +&
teEreliable.
General
tion Level
choose1
g forward
e your
n.
s in
ceJ=
Wesley Lai
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"t# $uly %&&'( &")&' P*
Tim Folkerts
r+m -deratr
egistration %ateF !ep $;;'
LocationF Kansas, !A
AgeF +;
ove.
nfortunately, there is no simple answer to your uestion. 5he ?".( formerly 4nown as
7IL@!5%@";+/ sampling plans are not based on specific statistical criteria.
5he AQL level is a defect rate that will usually get accepted. !o if your have AQL M $.+,
then lots with $.+& defective will probably get accepted. 5he probability depends on allsorts of factors. #or normal inspection, the number is typically around +&, it can be from
roughly ;@B& as I recall/. 5he batches have to be much worse typically '@"; times
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worse/ before you can be moderately sure of rejecting them.
5he only real way to judge the sampliong plans is to loo4 directly at the 9> curves and
tables at teh bac4 of the standard.
"a batch of 151-280pcs...AQL level 1.0 ... 95% accurate/reliable. Which e!eral !spectio!
Level #ust choose$"
#or a given AQL, you can loo4 up all the different sampling plans, then find the defect rate
that will be accepted +& of the time and the defect rate that will be rejected +& of the
time.
>9%)..!A7..)...+&......+&
..........!I?)................A>>)5
)........."'..........;...."...;.'(....$;.-
.........+;.........."....$...;.0"+....."(
N..........B;..........$...'....".;'.....0.--
K........."$+.........'...(....".;.....-.$;
L.........$;;.........+....-...".'".....+.$-
#or your eCample, the only sample si*es you would get for a batch of "+"@$B; are +;
Level II O III/ or "' all the other Levels/
for normal inspection. 5hat doesn6t give you very much fleCibility=
Another option is to design you own sampling plan. !elect the defect rate you will accept
+& of the time, the defect rate you will reject +& of hte time, adn find a sampling plan
that will wor4 for your needs.
5im #
PPPPPPPPPPPPPPPPPP
o &o!'er is to be(i! to u!'ersta!'.
/han0s t /im l0erts*r +r in*rmati&e Pst and1r Attachment!
+enaud
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%&t# ovember %&&'( )%& .*
gglntn"nacti&e Registered 2isitr
egistration %ateF 2ov $;;B
LocationF 7emphis, 52
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Re #$ t chse the crrect eneral "nspectin Le&el ' AQL le&el...(
>oncerning AQL, we use " gallon plastic bottles to pac4age product. >urrently bottles are
simply brought in the door with no incoming inspection, sent to the production floor, and
used, generally within $( @ (B hours. %uring production, as the operator manually puts the
bottles on the conveyor belt leading to the fill station, !/e inspects each one for defects,
debris, etc. %efective bottles are immediatlely counted and discarded.
!hould QA be doing incoming inspection, and if so, how would we go about chosing an
acceptEreject level for the lot, 4nowing that further down the line bottles will be ";;&
inspected by the production operator.
3hy would be ned to develop an AQL to reject the lot1 All that would do would be to add
an additional step. 5hnC
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/t# 0ecember %&&'( &')%& .*
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doing a sample inspection and the result compared with the AQL table will determine
rejection or acceptance of the goodsF
5he general inspection level II is what the norm calls the normal level. If you go to a
reduced I/ or tightened III/ level, the discriminatory ability of your inspection will be
different. Dou can switch to one of these levels if you have strong hints@@one way or
another@@about the uality level e.g. if the same supplier6s goods were rejected more thantwice over the last + inspections, you should go to level III.
I hope it helps.
#ena$d
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%2t# February %&&/( )24 .*
Stee&Appreciated "n*rmatin Res+rce
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AgeF +B
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EOA+5LE3 Lot o# 100 %nits, AQL o# 2(, o"&al Inspection and -in$le -a&plin$
Level I II III -1 -2 - -4
-a&ple -iGe 0 12 200 20 2
Aceptance %&'e" 10 0 0 1 1
C!en it is necessa"7 to dete"&ine an inspection level, a n%&'e" o# #acto"s &%st 'e
conside"ed in o"de" to opti&iGe t!e cost/"is "elations!ip( T!ese a"e3
a( T!e ope"atin$ c!a"acte"istic 8;: c%"ves to eval%ate t!e tec!nical p"ope"ties
o# va"io%s plans(
'( T!e s%pplie"
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AQL tables for prod"ct inspections
These statistical tables are fundamental tools for preparing a sampling plan for a random product inspection. They give you
the n!m"er of samples to inspect, and the maxim!m n!m"ers of defects that is alloed.
Thefirst ta"legives you the code letter for sampling. In this example, if the batch to check contains 5,000 pcs, and if you
choose level II (which is chosen by default for most inspections, the letter is !.
Thesecond ta"le(for normal severity gives you the useful information. The letter ! means "00 samples must be checked. If
you select the limits as ".5# for ma$or defects and %.0# for minor defects, you re$ect the batch if you find more than &0
ma$or and'or more than &% minor defects.
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!ore info abo"t the AQL
To understand the concept of the cceptance )uality !imit ()! in depth, you should read
this article*W#at is t#e .5L6.
nd here are the original )! charts, straight from the I+"-5 standard*
$hart %&
$hart '&
http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/ -
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$ac' to basics: (hat is the )AQL*+
by /enaud n$oran on "- ovember "0&&
The 1)! tables2 are statistical tools at the disposal of buyers (for product inspections. They help determine two key
elements*
How &an7 sa&ples s!o%ld 'e inspected
C!e"e is t!e li&it 'etween accepta'ilit7 and "e#%sal, w!en it co&es to de#ective
p"od%cts
The need for an objective measurement of quality
In virtually every production batch, there will be defective products. It is true even after the manufacturer has checked each
individual product and has repaired the defective ones.
Thus, in a supplier'buyer relationship, the supplier cannot be expected to deliver defect3free goods. 4owever, the buyer wants
to control the uality of purchased goods, since he does not want too many defects. 6ut what does 1too many2 mean7
4ow to set the limit between acceptability and refusal in a way that can be agreed upon and measured7
Definition and application of AQL
The limit, as described above, is called the 8)!9. It stands for 8cceptance )uality !imit9, and is defined as the 1ualitylevel that is the worst tolerable2 (I+ "-5 standard.
:or example* 1I want no more than &.5# defective items in the whole order uantity2 means the )! is &.5#.
In practice, three types of defects are distinguished. :or most consumer goods, the limits are*
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0P #o" c"itical de#ects 8totall7 %naccepta'le3 a %se" &i$!t $et !a"&ed, o" "e$%lations
a"e not "espected:( 2(P #o" &aDo" de#ects 8t!ese p"od%cts wo%ld %s%all7 not 'e conside"ed accepta'le
'7 t!e end %se":(
4(0P #o" &ino" de#ects 8t!e"e is so&e depa"t%"e #"o& speci#ications, '%t &ost %se"s
wo%ld not &ind it:(
These proportions vary in function of the product and its market. ;omponents used in building an airplane are sub$ect tomuch lower )! limits.
Gettin familiar !ith the AQL tables
6efore using the )! tables, you should decide on three parameters*
T!e lot siGeR( I# 7o% o"de"ed di##e"ent p"od%cts, t!e B%antit7 o# eac! p"od%ct is a lot
siGe, and sepa"ate inspections s!o%ld 'e ca""ied o%t #o" eac! lot( I# 7o% o"de"ed onl7
one p"od%ct, t!e lot siGe is 7o%" total o"de" B%antit7( T!e inspection level(.i##e"ent inspection levels will co&&and di##e"ent n%&'e" o#
sa&ples to inspect( In t!is a"ticle, we will stic to t!e socalled Klevel IIS, %nde" Kno"&alseve"it7S(
T!e AQL level app"op"iate #o" 7o%" &a"et( I# 7o%" c%sto&e"s accept very fewdefects, 7o% &i$!t want to set a lowe" AQL #o" 'ot! &aDo" and &ino" de#ects(
There are basically two tables. The first one tells you which 8code letter9 to use. Then, the code letter will give you the
sample si
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How to read this table?
>our code letter is 1!2, so you will have to draw "00pcs randomly from the total lot si
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Q: So, basicall- I have to a"thori.e the factor- to prod"ce some
defects+
* >es, some defects, since a factory cannot reasonnably be expected to turn out &00# good uality.
4owever, it does not mean the buyer tolerates everything as long as the number of defects are below the )! limits. Cleasesee below the note issued in the I+"-5 standard*
1lthough individual lots with uality as bad as the acceptance uality limit may be accepted with fairly high probability, the
designation of an acceptance uality limit does not suggest that this is a desirable uality level. +ampling schemes D...E aredesigned to encourage suppliers to have process averages consistently better than the )!.2
Q& Based on m* AQL- I calc!lated the proportion of defects a!thorized. h* dont the* correspond to the maxim!m
n!m"er of defects a!thorized#
* It is true. In our example above, ".5# of "00 samples is 5 samples, but we accept the goods even if &0 samples are foundwith a ma$or defect.
Fhy this difference7 There are heavy statistics behind this issue. To make it simple, the producer runs a risk of re$ection(based on the random element when drawing the sample even though his products (if they were all checked would be
accepted. nd, in the same logic, the consumer runs a risk of accepting bad products. The statisticians had to account forthese risks, that9s why the numbers were ad$usted and seem not to make sense.
Q: h- not &"st sa-, /(e0ll chec' 12 of the 3"antit-0, or (hatever
percentage deemed appropriate+
* 4ere again, the statisticians tell us it is not that simple. s we go up in the total uantity, the proportion of productschecked can decrease, for the same confidence in the inspection results.
s you can see in the chart below, the number of samples to check (vertical axis increases at a slower pace than the totaluantity (hori
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How &an7 sa&ples s!o%ld 'e inspected
C!e"e is t!e li&it 'etween accepta'ilit7 and "e#%sal, w!en it co&es to de#ective
p"od%cts
The need for an objective measurement of quality
In virtually every production batch, there will be defective products. It is true even after the manufacturer has checked eachindividual product and has repaired the defective ones.
Thus, in a supplier'buyer relationship, the supplier cannot be expected to deliver defect3free goods. 4owever, the buyer wantsto control the uality of purchased goods, since he does not want too many defects. 6ut what does 1too many2 mean7
4ow to set the limit between acceptability and refusal in a way that can be agreed upon and measured7
Definition and application of AQL
The limit, as described above, is called the 8)!9. It stands for 8cceptance )uality !imit9, and is defined as the 1ualitylevel that is the worst tolerable2 (I+ "-5 standard.
:or example* 1I want no more than &.5# defective items in the whole order uantity2 means the )! is &.5#.
In practice, three types of defects are distinguished. :or most consumer goods, the limits are*
0P #o" c"itical de#ects 8totall7 %naccepta'le3 a %se" &i$!t $et !a"&ed, o" "e$%lations
a"e not "espected:( 2(P #o" &aDo" de#ects 8t!ese p"od%cts wo%ld %s%all7 not 'e conside"ed accepta'le
'7 t!e end %se":(
4(0P #o" &ino" de#ects 8t!e"e is so&e depa"t%"e #"o& speci#ications, '%t &ost %se"s
wo%ld not &ind it:(
These proportions vary in function of the product and its market. ;omponents used in building an airplane are sub$ect tomuch lower )! limits.
Gettin familiar !ith the AQL tables
6efore using the )! tables, you should decide on three parameters*
T!e lot siGeR( I# 7o% o"de"ed di##e"ent p"od%cts, t!e B%antit7 o# eac! p"od%ct is a lot
siGe, and sepa"ate inspections s!o%ld 'e ca""ied o%t #o" eac! lot( I# 7o% o"de"ed onl7
one p"od%ct, t!e lot siGe is 7o%" total o"de" B%antit7( T!e inspection level(.i##e"ent inspection levels will co&&and di##e"ent n%&'e" o#
sa&ples to inspect( In t!is a"ticle, we will stic to t!e socalled Klevel IIS, %nde" Kno"&alseve"it7S(
T!e AQL level app"op"iate #o" 7o%" &a"et( I# 7o%" c%sto&e"s accept very fewdefects, 7o% &i$!t want to set a lowe" AQL #o" 'ot! &aDo" and &ino" de#ects(
There are basically two tables. The first one tells you which 8code letter9 to use. Then, the code letter will give you the
sample si
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4ow to read this table7 It is very easy.
If you follow my example, I assume your 8lot siour code letter is 1!2, so you will have to draw "00pcs randomly from the total lot si
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5"od%ct con#o"&it7 8aspect, wo"&ans!ip:( I# all t!e p"od%cts a"e in "ed colo"
instead o# o"an$e, t!e"e is no need to co%nt eac! sa&ple as a de#ect( It &aes &o"esense to "e#%se #o" p"od%ct con#o"&it7(
-peci#ic tests de#ined in t!e inspection c!eclist 8t!e7 &i$!t not 'e pe"#o"&ed on all
inspected sa&ples i# t!e7 a"e ti&econs%&in$ o" dest"%ctive:(
To o further
,elated articles& all the basics an importer should know about uality control are explained in the articles listed on t#ispage.
A!thor& /enaud n$oran is an expert in uality assurance and uality control. 4is agency helps buyers in ;hina. *ore info#ere.
"requently as#ed questions about AQL
Q: hat are the red"ced and tightened inspection severities+
* They are designed to be used in very specific situations, when a producer is particularly reliable, or on the contrary fails
too often. In practice, these severities are used in less than of ); inspections.
The normal severity already allows for a good variation of sample sies, some defects, since a factory cannot reasonnably be expected to turn out &00# good uality.
4owever, it does not mean the buyer tolerates everything as long as the number of defects are below the )! limits. Cleasesee below the note issued in the I+"-5 standard*
1lthough individual lots with uality as bad as the acceptance uality limit may be accepted with fairly high probability, thedesignation of an acceptance uality limit does not suggest that this is a desirable uality level. +ampling schemes D...E are
designed to encourage suppliers to have process averages consistently better than the )!.2
Q& Based on m* AQL- I calc!lated the proportion of defects a!thorized. h* dont the* correspond to the maxim!m
n!m"er of defects a!thorized#
* It is true. In our example above, ".5# of "00 samples is 5 samples, but we accept the goods even if &0 samples are foundwith a ma$or defect.
Fhy this difference7 There are heavy statistics behind this issue. To make it simple, the producer runs a risk of re$ection
(based on the random element when drawing the sample even though his products (if they were all checked would beaccepted. nd, in the same logic, the consumer runs a risk of accepting bad products. The statisticians had to account for
these risks, that9s why the numbers were ad$usted and seem not to make sense.
Q: h- not &"st sa-, /(e0ll chec' 12 of the 3"antit-0, or (hatever
percentage deemed appropriate+
* 4ere again, the statisticians tell us it is not that simple. s we go up in the total uantity, the proportion of products
checked can decrease, for the same confidence in the inspection results.
s you can see in the chart below, the number of samples to check (vertical axis increases at a slower pace than the total
uantity (hori
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Q& Ho to choose an AQL limit for m* prod!cts#
*See t#is article.
'eter
Aoes a ?a$or defect also count towards the ?inor defect count7Gsing your above example (=,"0&3&0,000, level II, ",5H%, what if the result of the inspection was ?a$or and &=
?inor. Ao the ?a$ors also count towards the ?inor total, for a total of "" defects that are at least ?inor7 r, arethey always kept separate7
#ena$d (n)oran
o. 6etter always keep them separate.
Ty*ho +ro$wstra
6etter7 ctually keeping them separate has funny conseuences. If the minor defective allowance is exceeded a bit
while the ma$or'critical defect allowances still left some spare room, the )! system would effectivelyrecommend suppliers to smash a few products so that all allowances would be met again.
,ohn+$o
lthough it seems like it, this is actually not right thinking. ThatJs because there might be totally differentmanufacturing mistakes that can lead to ma$or and minor mistakes. +o if you have found only & ma$or defect and
then more minor defects you cannot group them together since you might end up with a whole bunch of productshaving the same minor mistake. Then, although there would be only a few pcs of ma$or ones the whole lot would
become unacceptable by the end client. )! has its flaws anyway, like any system i guess, and can be very unfairfor the supplier or the buyer, (usually the buyer though. K
#ena$d (n)oran
ThatLs right. AonLt ask me to defend that methodLs logic... I am $ust explaining how it is supposed to be applied.
(ndrew
4ello /enaud,
!et9s say an assembly line is producing "000 products a day therefore sample volume would be &"5, with MB andM&0 ma$or and minor defects. 4owever sampling all &"5 at once is not practical and hourly tests want to be done.
!et9s say &0 an hour for a &N hour day to cover all options. ow does the MB and M&0 ma$or and minor defects haveto be totaled up for the whole day or can it be split up into the hourly tests in order to not slow down the assembly
line. lso can figures be modified to fit the company, it is not a food product and safety is not of concern, $ustsending out a uality product however the defect limits provided on the )! charts seem a little intense. Thanks
http://www.qualityinspection.org/how-to-choose-an-aql-limit/http://www.qualityinspection.org/how-to-choose-an-aql-limit/http://www.qualityinspection.org/how-to-choose-an-aql-limit/http://disqus.com/guest/6ea3d36a7207ed981189957a5e37d7ac/http://disqus.com/RenaudAnjoran/http://disqus.com/google-af775587ff310bfd8a96e9bff112f7a8/http://disqus.com/guest/662b36df8da977c14511941b885262bf/http://disqus.com/RenaudAnjoran/http://disqus.com/disqus_yvXOr3dZOw/http://www.qualityinspection.org/wp-content/uploads/2011/11/sample-size-relative-to-lot-size.jpghttp://www.qualityinspection.org/how-to-choose-an-aql-limit/http://disqus.com/guest/6ea3d36a7207ed981189957a5e37d7ac/http://disqus.com/RenaudAnjoran/http://disqus.com/google-af775587ff310bfd8a96e9bff112f7a8/http://disqus.com/guest/662b36df8da977c14511941b885262bf/http://disqus.com/RenaudAnjoran/http://disqus.com/disqus_yvXOr3dZOw/ -
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(ndrew
n a side note, products get shipped out randomly however they are packed &5 to a crate, would it be wiser to testeach crate individually (lots si
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.atthew&amenstein
4ello,
If we have & item that is a &0 pc set, if we purchase as & pc, and we order 5000 &0 pc sets, is the al sample si
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(drian
4i /enaud,
re there any method that we can faster the +ampling process by reducing the sample si
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looks at the nails, are the defects still &0'&% or is our sample si
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#ena$d (n)oran
The lot uantity is the actual uantity to ship.+pecial case* if the supplier is late in packing and some pieces to be shipped are still unpacked, they are part of the
lot.
'eter
Is there any benefit to performing the same inspection on the same lot7!etLs say that my factory does a ".5 )! !evel III inspection. Is there any benefit to having a =rd party inspect the
same lot at ".5 )! !evel III after the factory completes its inspection7
/
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+enaud .n?oran+odPeter= mont#s ago
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o. 6etter always keep them separate.
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Flag as inappropriate
6etter7 ctually keeping them separate has funny conseuences. If the minor defective
allowance is exceeded a bit while the ma$or'critical defect allowances still left some spare
room, the )! system would effectively recommend suppliers to smash a few products so thatall allowances would be met again.
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Fo!n%o,yc#o :rouwstra% days ago
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lthough it seems like it, this is actually not right thinking. ThatJs because there
might be totally different manufacturing mistakes that can lead to ma$or and minormistakes. +o if you have found only & ma$or defect and then more minor defects youcannot group them together since you might end up with a whole bunch of products
having the same minor mistake. Then, although there would be only a few pcs ofma$or ones the whole lot would become unacceptable by the end client. )! has its
flaws anyway, like any system i guess, and can be very unfair for the supplier or thebuyer, (usually the buyer though. K
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+enaud .n?oran+od,yc#o :rouwstraa mont# ago
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ThatLs right. AonLt ask me to defend that methodLs logic... I am $ust explaining how it
is supposed to be applied.
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4ello /enaud,
!et9s say an assembly line is producing "000 products a day therefore sample volume would be &"5, with MB and
M&0 ma$or and minor defects. 4owever sampling all &"5 at once is not practical and hourly tests want to be done.!et9s say &0 an hour for a &N hour day to cover all options. ow does the MB and M&0 ma$or and minor defects have
to be totaled up for the whole day or can it be split up into the hourly tests in order to not slow down the assemblyline. lso can figures be modified to fit the company, it is not a food product and safety is not of concern, $ust
sending out a uality product however the defect limits provided on the )! charts seem a little intense. Thanks
see more
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n a side note, products get shipped out randomly however they are packed &5 to a crate, would it be
wiser to test each crate individually (lots si
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+enaud .n?oran+od.ndrew" mont#s ago
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single3stage sampling plan is probably not the most appropriate in your situation. 4ere is
what I would advise*1;ontinuous sampling2 is the best plan when products are made individually in a continuousflow. It makes no sense to pick samples inside each 1batch2. It consists of several phases*
3 t the beginning, each piece is checked (that9s the 1screening2.3 fter a certain number of pieces were found satisfactory, only certain pieces are checkedrandomly (that9s the 1sampling2.
3 If a piece is defective* back to screening.
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.ndrew+enaud .n?oran" mont#s ago
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Cerfect thank you,Is there separate )! tables for this method or do you $ust choose numbers that fit
your process, say screen 50 then randomly check &0 every hour. lso the companywants a paper trail would you advise to $ust record any failures during screening then
record the random sampling 7 thanks
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+enaud .n?oran+od.ndrew" mont#s ago
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AonLt worry about tables. This calculator will give you all the settings youneed*
#ttp)88www9s7conline9com8mil-s999
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-ital s!et"i= mont#s ago
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If i am buying &00000 pairs of loge and coated on the pack al&.5 so what does it men7It means &500 pairs defected7Cl< help me to solve the problem.
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+enaud .n?oran+odSital k ks#etri% mont#s ago
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o, itLs a bit more complicated than that... >ouLd have to read the article above.
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.n guyen% mont#s ago
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Aear /enaud,
ILve read this inspection information*+ample si
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http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778414653http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778414653http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778414653http://www.qualityinspection.org/what-is-the-aql/#comment-778524815http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778414653http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778414653http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778414653http://www.qualityinspection.org/what-is-the-aql/#comment-778524815http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/ -
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There not enough information for me to understand this sampling plan... O& might refer to generallevel I. ThatLs all I can guess.
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.n guyen+enaud .n?oran% mont#s ago
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Thanks for your response.
This is the document ILve read*
http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778524815http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778524815http://www.qualityinspection.org/what-is-the-aql/#comment-778533861http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778524815http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/#comment-778524815http://www.qualityinspection.org/what-is-the-aql/#comment-778533861http://www.qualityinspection.org/what-is-the-aql/http://www.qualityinspection.org/what-is-the-aql/ -
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+enaud .n?oran+od.n guyen% mont#s ago
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:or the &st inspection, I guess you should follow level I.
:or the "nd inspection, it is not clear.
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In the example you gave, they were not clearly. :or ex* If I find out there are &- minor defects and 5 ma$or defects ,
so how can I $udge this Co will be passed or re$ected7 In my experience, If the total defects are not over "% defectsand over &0 ma$or defects this Co will be accepted to release. Is it right or not7 Clease kindly advice.
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If the number of minor defects is above the tolerance, the overall result is :I!@A. @ven if the ma$ordefects are below the tolerance.
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4ello ?r n$oran,Aepend on your idea , which is the higher uality between the two cases I will give youAuring the inspection with the same uantity as your example , &st case* &- minor defects, Nma$or defects. "nd case* &% minor defects, &0 ma$or defects.
Clease advice and help me to $udge which will pass the inspection.
Thank youP
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+enaud .n?oran+odguyen .n# ,oan% mont#s ago
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If you decide to follow this standard and to set )! tolerances, it can be very dumb.There is no need to look for logic in all the special cases. In some special cases it is$ust dumb. I am not defending this standard at all. I am $ust explaining how it works
in practice.
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guyen .n# ,oan+enaud .n?oran% mont#s ago
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4iP
infact, Auring the inspection we will meet these situations and you mustmake the decision this Co will pass or not. The suppliers want to know this
so that they will ship this Co or not. +o you should list all the cases
including the special cases, the examples which I showed to you are notspecial alot. the impotant things are that how could you convince thesuppliers this or that order pass or fail the inspection. +ometimes, the minor
defects are over the )! but It will be passed the inspection. If theinspector can not make his or her decision on the orders he or sheconducted . what will the suppliers thinking about the inspectors7 the two
examples I gave you , all passed the )! , and the fisrt case the uality isbetter than the second. The total defects should not be over "% defects ( thefisrt condition and the ma$or defects should not be over &0 defects ( the
second condition. nyway thanks for your document because there arealot of document are very usefull for the inspectors, I would like to remind
you that when doing the inspection in practice the logic is very important.
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4ello,
If we have & item that is a &0 pc set, if we purchase as & pc, and we order 5000 &0 pc sets, is the al sample si
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*att#ew@amenstein" mont#s ago
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4i, I am totally confused about dphu. +ay I have a lot of %000, sample si
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Oood point. I answered it in the =rd )H on this page, actually.
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*att#ew@amenstein+enaud .n?oran" mont#s ago
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+orry, but I do not see the answer below.
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+enaud .n?oran+od*att#ew@amenstein" mont#s ago
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I mean, it is toward the end of the article. 6ut I am also pasting it here*
)* 6ased on my )!, I calculated the proportion of defects authori
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o >o
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If we test &00# of our products, does this still applies7 ILm guessing not unless I missed something.
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+enaud .n?oran+odSmarties3/3 mont#s ago
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o, this is only applicable if you do random sampling.
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Ad"ian3 mont#s ago
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4i /enaud,
re there any method that we can faster the +ampling process by reducing the sample si
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+ure, there are ways to do this. >ou can read this article* #ttp)88www97ualityinspection9o999.
/egarding normal'reduced'tightened* these are the different severities, not the different levels. ?ore info
on#ttp)88www97ualityinspection9o999.
nd a good summary of all these concepts is on #ttp)88www97ualityinspection9o999.
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Ad"ian3 mont#s ago
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many thanks for your explanation, really helpful
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Ad"ian3 mont#s ago
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very nice explanation, i would like to ask some uestion about )!*&. If I found & ma$or and & minor defect on one unit, which type of defect is used, ma$or (cause its greater than theminor or count separately & ma$or defect and & minor defect7
". example lot si
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&. nly count the ma$or defect. AonLt count the minor defect.". ;ount & ma$or defect only on that unit.
ote* what you call a unit should be the smallest selling'usable unit.
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+oy *artine12 mont#s ago
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Is there an exception to critical defects having an inspection that passes 7 r is it always 0'&
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+enaud .n?oran+od,imbo4 mont#s ago
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Timbo,
I strongly advise you to consider that the lot is "00,000 nails, rather than ",000 boxes. ;ount it all inpieces.
+ee#ttp)88www97ualityinspection9o999for more details.
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E"i= mont#s ago
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4i /enaud,thanks, your explanation is very simply.
I have a uestion* are there values )! internationally recogni
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+enaud .n?oran+odArik= mont#s ago
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>es, this standard can be applied on any products (finished or unfinished, instances of a process, etc.
6ut you should adapt the values of the )! to your product and your market. ;lck on the last link, at thebottom of the article, if you are wondering how to do that.
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:ail ;irks= mont#s ago
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excellent explanation of what can be a complex concept. thanks
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