Every defect observed during inspection is categorized into three standard levels:
- Critical: Defects that create hazardous or unsafe conditions for the user, or violate mandatory legal / regulatory requirements (e.g. banned substances, sharp points, choking hazards, missing safety labeling).
- Major: Defects that materially reduce functionality, structural integrity, or durability, or obvious visual flaws that significantly impact salability / brand presentation.
- Minor: Defects unlikely to impair function, but which may negatively affect perceived quality or shelf appeal (e.g. minor cosmetic scuffs, uneven stitching within tolerance).
Key Counting Rules (Applied to Every Random Inspection)
1. One defect per sample rule: If a single sample carries multiple defects, only the most severe defect is counted against the AQL result (e.g. a unit with both a Major and a Minor → counted once as Major).
2. Critical = Stop: If any Critical defect is found, the entire shipment is rejected in principle. We immediately escalate to the client for a formal disposition decision before release.
3. AQL Decision: Final result (PASS / FAIL) is determined strictly by comparing actual defect counts against the AQL acceptance/rejection numbers in the sampling plan table.