How to Read an Underwear Inspection Report: AQL, Defects, and Pass/Fail Criteria
📋 Direct Answer: An underwear inspection report uses AQL 2.5 standard: for a 10,000-unit order, inspect 200 pieces randomly. Up to 10 major defects OR 14 minor defects = pass. Critical defects (metal fragments, safety hazards) = zero tolerance — even one triggers automatic rejection. The report is only as useful as your ability to read it.
How to Read an Underwear Inspection Report: AQL, —
An inspection report is only as useful as your ability to read it. Many OEM buyers receive inspection reports without understanding what the numbers actually mean. Here’s how to interpret an underwear inspection report and make informed pass/fail decisions.
AQL Sampling Explained
AQL (Acceptable Quality Level) determines how many units to inspect and the maximum allowable defects. For a 10,000-unit order at AQL 2.5 (Level II): sample size is 200 units. Maximum allowed major defects: 10 (5%). Maximum allowed minor defects: 14 (7%). If the sample has 11 major defects, the lot fails — even though 11/10,000 is 0.11%.
Defect Classification
Critical: Safety hazard or legal non-compliance. Zero tolerance. Example: exposed needle, wrong fiber content label. Major: Affects functionality or salability. Example: seam break, size deviation over 5%, color shading. Minor: Does not affect functionality. Example: loose thread under 1cm, slight fold mark.
Reading the Report
1. Check the sample size and AQL level used. 2. Review critical defects first — any critical = automatic fail. 3. Count major defects vs allowable. 4. Review defect photographs. 5. Check measurement report (average and range per size). 6. Confirm packaging and labeling compliance.
Decision Framework
| Defect Type | AQL Standard | Action If Exceeded | Example |
|---|---|---|---|
| Critical | Zero tolerance | Reject entire lot | Metal fragment, broken needle |
| Major | AQL 2.5 | Reject & rework entire lot | Seam break, size deviation >5% |
| Minor | AQL 4.0 | Accept with discount or rework | Loose thread, slight color variation |
Pass (defects under AQL): Accept shipment. Conditional Pass (borderline): Accept with discount or rework specific defects. Fail (over AQL): Reject lot, require re-inspection after rework. Contact Unitex for inspection report interpretation and QC process details.
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Q: How many pieces should be inspected?
A: Per AQL 2.5 Level II: 200 pieces from a 10,000-unit lot, 315 pieces from 35,000 units, and 500 pieces from 150,000+ units. The inspection quantity scales with lot size — not a fixed percentage.
Q: What if my factory sends their own inspection report?
A: Never rely solely on factory self-inspection. Always arrange independent third-party inspection (SGS, Bureau Veritas, Intertek, or your own QC team). Factory inspection reports have an inherent conflict of interest — the same person who approved production is grading the results.
Standard: Based on ISO 2859-1 / ANSI ASQ Z1.4 sampling standards for attribute inspection by lot size. These are the global apparel industry benchmarks used by major retailers including Walmart, Target, H&M, and Zara for third-party quality verification.
· Xiamen Unitex Trade Co., Ltd. — OEM & ODM underwear sourcing partner
Unitex Underwear (Xiamen Unitex Trade Co., Ltd.) — OEM/ODM underwear sourcing and supply-chain partner in Xiamen, China; in the trade since 2009, incorporated in 2013.