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Acceptable Quality Level (AQL) is a statistical method that helps you determine the quality of your products based on a sample inspection. It is a method of determining how many flaws in a batch of goods must exist before you reject them all.
In terms of defective units as a percentage or ratio of all units, AQL is expressed. An AQL of 1%, for instance, allows you to accept up to 1 damaged unit out of every 100 inspected units. Having an AQL of 0.65 allows you to accept up to 0.65 defective units out of every 100 tested units.
The greater the quality level you are establishing for your items, the lower the AQL. This calls for extra inspections, though, and increases the likelihood that the entire batch may be rejected if there are too many flaws.
The AQL you choose depends on several factors, such as:
- The type and severity of defects: Certain flaws are more serious than others and may compromise the usability or safety of your items. A damaged zipper on a jacket, for instance, is more serious than a loose thread on a blouse. Consider lowering the AQL for critical errors while raising it for minor ones.
- The cost and risk of defective products: Some goods cost more to make or are riskier to sell than others. For instance, a faulty medical gadget may endanger the user or subject the manufacturer or seller to legal repercussions. For high-priced or high-risk products, you might want to establish a lower AQL; for low-priced or low-risk products, you might want to set a higher AQL.
- The expectations and requirements of your customers: When it comes to expectations for product quality, some clients are more rigid or demanding than others. For instance, a luxury brand might hold itself to greater standards of quality than a bargain retailer. Customers who demand great quality may require a lower AQL, whereas consumers who are more accommodating or tolerant may require a higher AQL.
AQL is crucial since it enables you to make sure that your items satisfy your clients and adhere to your quality requirements. Also, it helps you avoid wasting time and money by rejecting too many lots or evaluating an excessive number of units.
Unfortunately, the AQL does not ensure quality. You can only assess the quality level using this statistical technique, which bases its estimation on a sample examination. It does not provide information on the precise amount of flaws in your items or how well they will function in actual use.
Therefore, you should always use AQL in combination with other quality control methods, such as:
- Pre-production inspection: Check the production methods, raw materials, and components before launching a large production.
- In-process inspection: Examine the goods at various phases of production to find and address any flaws as soon as possible.
- Final inspection: Prior to delivery to your customers or warehouse, inspect the finished products.
- Customer feedback: Gathering and evaluating consumer feedback following delivery and use of your items.
