AQL Sampling Calculator

Welcome!

Calculate AQL. Simply Upload Packing List/PO or add data.

Mode
Inspection Levels & Defects Classification
General LevelSpecial Level
Major AQLMinor AQL
Packing List/PO Details
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SR Style Description Color Size Quantity Cartons
TOTAL 0 0

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Go to Calculator, enter your lot details, click Calculate, then Save.

AQL Table

ANSI/ASQ Z1.4-2008 reference tables for Normal inspection.

Table I — Sample Size by Lot Size
Look up your lot size and inspection level to get the sample size.
Lot Size S1 S2 S3 S4 I II III
Table II-A — Ac / Re by Sample Size
Ac = Accept if defects ≤ Ac. Re = Reject if defects ≥ Re. Highlighted columns show the industry defaults.
Quick Reference

General Levels — Used for visual inspection of finished goods.

  • Level I — Reduced inspection. Use when supplier history is good and risk is low.
  • Level II — Standard. Used in most inspections (default).
  • Level III — Tightened. Use when quality issues exist or risk is high.

Special Levels (S1–S4) — Used for measurements and testing where smaller sample sizes are acceptable.

Common AQL — Major 2.5, Minor 4.0 (industry defaults).

Features & Guides

What this app does, and how to use it correctly.

What This App Does

AQL Calculator finds your AQL Sample size based on lot quantity. It also calculates quantity you should pick per style & per color & per size & number for cartons for each color & size.

This app is based on the internationally recognized US Standard MIL-STD-105E, ANSI/ASQ Z1.4 standard & EU Standard ISO 2859-1.

Key Features
  1. Sample Size Calculation — Enter lot quantity, inspection level, and AQL. Get the exact sample size.
  2. Two Sampling Modes — Combined AQL (one Sample Size for the whole lot) or AQL per style(separate sample size).
  3. Major & Minor AQL — Set different AQL values for each defect class.
  4. General & Special Levels — General I/II/III for sample size; Special S1–S4 for measurements and testing.
  5. Proportional Distribution — Sample size and carton count spread across every Style → Color → Size position.
  6. Carton Selection — Based on √(total cartons), distributed proportionally.
  7. Pick Ctns & Qty/Ctn — Shows cartons to pick and pieces per carton.
  8. Export & Share — Download as CSV or print.
  9. Save & Reuse — Save any calculation, reopen later, or merge rows from a saved file.
  10. Works Offline — Once loaded, no internet needed. Data stays on your device.
Guide 1 — How to Choose Sample Size Based on Quantity

The Z1.4 standard maps your lot quantity and inspection level directly to a sample size.

Step 1 — Pick your inspection level.

  • General II is the default. Use it unless you have a reason to change.
  • General I gives a smaller sample. Use it when the supplier has a strong track record and the product risk is low.
  • General III gives a larger sample. Use it when there have been quality problems, or the product is high-risk.

Step 2 — Find your sample size. Use the AQL Table tab, or the app calculates it for you automatically.

Step 3 — Read the Ac/Re numbers. With the sample size and your AQL, look up the Accept and Reject numbers.

Special Levels S1–S4 are for measurement-based inspections. They produce much smaller samples.

Guide 2 — How to Choose AQL Based on Defect Type

Defect classes

  • Critical — Safety or legal issues. Typically zero tolerance (AQL 0).
  • Major — Function failure or obvious flaw. Most common AQL: 2.5.
  • Minor — Cosmetic or minor deviation. Most common AQL: 4.0.

Choosing the AQL value

The AQL is the maximum defect rate you are willing to accept. A lower AQL means stricter inspection.

  • High-value or safety-critical products → use a lower AQL (e.g. 1.0 or 1.5 for Major).
  • Standard consumer goods → use 2.5 for Major and 4.0 for Minor.
  • Low-risk items or accessories → 4.0 Major and higher Minor may be acceptable.

Reading Ac / Re

Once you have a sample size and AQL, the Z1.4 table gives you Ac (Accept number) and Re (Reject number).

  • If the number of defects found ≤ Ac → Accept the lot.
  • If the number of defects found ≥ Re → Reject the lot.

Worked example

Lot size 20,000, General II, Major AQL 2.5, Minor AQL 4.0:

  • Sample size = 315
  • Major 2.5 → Ac = 14, Re = 15
  • Minor 4.0 → Ac = 21, Re = 22

So: inspect 315 pieces. Accept if ≤14 Major and ≤21 Minor defects. Reject if ≥15 Major or ≥22 Minor.

Who It's For
  • QA & QC inspectors
  • Factory quality teams
  • Buying offices & sourcing agents
  • Third-party inspection agencies
  • Anyone performing AQL-based inspections
Based On

US Standard MIL-STD-105E, ANSI/ASQ Z1.4-2008 — Sampling Procedures and Tables for Inspection by Attributes.

EU Standard ISO 2859-1 — Sampling Procedures for Inspection by Attributes — Part 1.