AQL Inspection Guide: How Kexin Quality-Checks 1,200+ Batches per Year
How AQL inspection works in B2B protective case orders. ISO 2859-1 sampling, 1,200+ batches, real cases.
Direct answer: Kexin runs AQL 2.5 inspection on every B2B batch — 1,229/1,247 batches passed in 2024-2025 (98.6% pass rate). Critical defects AQL 1.0 (zero tolerance) is mandatory. Sample sizes follow ISO 2859-1 General Level II, with reduced Level I for orders under 500 pieces. Per-batch inspection report: USD 50.
What is AQL?
AQL (Acceptable Quality Level) is a statistical sampling system per ISO 2859-1. It determines sample size for a given lot size to accept/reject batches with 95% confidence. For B2B cases, standard is AQL 2.5 (Major defects) and AQL 1.0 (Critical defects, zero tolerance).
3-Tier AQL System
- Critical (AQL 1.0): zero tolerance — wall thickness below spec, cracks, broken latches, hinge failure
- Major (AQL 2.5): 2.5% acceptable — scratch > 5mm, dent > 10mm, foam error > 2mm
- Minor (AQL 4.0): 4% acceptable — minor scratch, paint bubble, slight color variation
Sample Size — ISO 2859-1 General Level II
For 1,000-piece order: 80 sample units (Major), 50 (Critical). For 5,000-piece: 125 (Major). For 10,000+ piece: 200 (Major). Inspection time: 3-4 hours for 130 units.
Real Cases (2024-2025)
Case 1: German defense agency (8,000 cases, Q2 2024). First batch 1,200 cases: 1.8% major defect (uneven O-ring seal, 22 cases) — exceeded AQL 2.5. Action: 8D report, tool reground, SPC chart, 100% seal check. Subsequent 6,800 cases: 0 critical, 0.3% major — saved €740,000 order.
Case 2: US medical OEM (12,000 cases, Q4 2024). AQL found 3 cases with particles > 0.5mm. Action: ISO 8 cleanroom, 5,000 K LED inspection. Subsequent 10,000 cases: 0 particle defects, FDA passed, 50,000 cases/year 2025 framework signed.
Case 3: Dutch drone integrator (3,500 cases, Q1 2025). 4 cases wall 2.4mm (spec 2.6mm ± 0.1). Action: temperature +5°C, cooling +3s, AQL sample to 32, 100% ultrasonic. 3,500 cases: 100% IP67 passed, Cpk 1.67.
What Kexin Provides
- AQL 2.5 report per batch (USD 50) — signed by QC engineer with photos
- Pre-shipment photos (10-20 random) — free
- Customer-arranged inspection — SGS, BV, TUV welcome (USD 200-400/day + travel)
- Rejection handling — re-inspect 100%, replace at our cost (+5-7 days)
FAQ
Can I request AQL 1.5 or 4.0?
Yes. AQL 1.5 for defense/medical, AQL 4.0 for cost-sensitive non-critical. Pricing unchanged.
What about FDA cleanroom?
ISO 8 cleanroom final assembly (Class 100,000). +5 days, +USD 5-8/case. FDA report and IQ/OQ/PQ docs provided.
Can I inspect at your factory?
Yes. Free factory tour + inspection station. Customer pays inspector fees. 7 days advance notice.