Quality control in global sourcing is the process of verifying that goods match the buyer's specification before they leave the factory. It happens in three stages: pre-production (materials and setup), during production (inline), and pre-shipment (finished goods). Skipping inspection is the most expensive decision in sourcing.
The Three Stages of Quality Inspection
Conducted before production begins. Verifies that raw materials, components, and production setup match the approved specification. Catches problems before they are built into 10,000 units.
Conducted when 10–40% of goods are produced. Samples finished units from the production line and checks against spec. Allows corrections while production is still in progress.
The most widely used inspection type. Conducted when 100% of goods are produced and at least 80% are packed. Inspector samples the shipment against the buyer's QC checklist before payment is released.
AQL Sampling — What It Means and How to Use It
AQL stands for Acceptable Quality Limit. It is a statistical sampling standard that defines how many defects in a sample are acceptable before a shipment is rejected. The AQL number represents the maximum defect rate (as a percentage) that is considered acceptable for a given product.
Most buyers use AQL 2.5 for major defects and AQL 4.0 for minor defects. For critical defects (safety or regulatory issues), AQL 0 is standard — zero defects accepted.
| AQL Level | Typical Use | Defect Rate Threshold |
|---|---|---|
| AQL 0 | Critical defects (safety, regulatory) | Zero tolerance |
| AQL 1.0 | Medical devices, precision products | Very strict — 1% |
| AQL 2.5 | Major defects — most consumer products | Standard — 2.5% |
| AQL 4.0 | Minor defects — cosmetic issues | Relaxed — 4% |
| AQL 6.5 | Packing and labelling checks | Lenient — 6.5% |
The sample size is determined by the total shipment quantity and the inspection level (usually General Inspection Level II). Plutonia uses AQL 2.5 / 4.0 as standard for most orders, with tighter criteria applied to regulated products.
What Does a Quality Inspection Report Contain?
A professional inspection report includes: the inspection date, factory name and address, total quantity produced and packed, sample size inspected, defects found (classified as critical, major, minor), photographs of each defect type, carton and packaging check results, measurement results against spec, and a clear pass/fail conclusion with the AQL result.
Plutonia inspection reports are delivered within 24 hours of inspection completion, with photographs, defect classification, and a recommended action where the result is borderline or fail.