Textile defects range from incorrect sizing and colour shade variations to stitching failures and fabric flaws. In workwear, defective stitching or non-compliant fabric can compromise worker safety. For fashion, quality inconsistencies damage brand reputation.
The textile industry commonly uses AQL 1.0 to 4.0 depending on the product tier. Workwear and PPE require tighter levels (1.0), while basic garments may accept AQL 2.5 or 4.0 for minor defects.
| Defect Type | AQL | Inspection Level | Notes |
|---|---|---|---|
| Critical (needle contamination) | 0 | General II | Metal detection mandatory |
| Major (stitching, sizing, colour) | 2.5 | General II | Most common inspection level |
| Minor (loose threads, marks) | 4.0 | General I | Buyer tolerance varies |
AQL 2.5 inspection of 10,000 polo shirts revealed that 8% were 2cm shorter than spec. The lot was rejected, preventing mass customer returns and saving an estimated $150,000 in reverse logistics.
Pre-shipment inspection at AQL 1.0 confirmed all hi-vis workwear met EN ISO 20471 reflective tape placement and seam strength requirements.
A broken sewing needle was found embedded in a garment during metal detection. Full lot screening revealed two more needles, highlighting the importance of 100% metal detection alongside AQL sampling.
