Sub.

- Fabric Quality Assurance

Sampling and
Inspection
Mentor- Mr. Sumit Kumar Sir

Presented by- Mansi Gautam

Textile Design Department
Semester- 6th (3rd Yr)
What is Sampling?
Sampling is the process by which a sample is
collected from a large number of materials.
A sampling plan allows an auditor or a
researcher to study a group (e.g. a batch of
products, a segment of the population) by
observing only a part of that group, and to
reach conclusions with a pre-defined level of
certainty.
The methodology used to sample from a larger
number of products depending on which type of
analysis being performed,
Textile sampling depends on few factors such as
the form of the material, amount of material
available, nature of the test etc.
SAMPLING TECHNIQUES
 In a simple random sample of a given size, all subsets of a
sampling frame have an equal probability of being selected.

Each element of the lot thus has an equal probability of

selection. Furthermore, any given pair of elements has the same
chance of selection as any other such pair. This minimizes bias
and simplifies analysis of results.

Simple random sampling can be vulnerable to sampling error

because the randomness of the selection may result in a sample
that doesn't reflect the makeup of the whole lot.

Simple
Sampling
 Systematic sampling is also known as interval sampling.

It relies on arranging all the subsets according to some

ordering scheme and then selecting elements at regular
intervals through that ordered list.

Systematic sampling involves a random start and then

proceeds with the selection according to the ordering
scheme element from then on wards.

As long as the starting point is randomized, systematic

sampling is a type of probability sampling. It is easy to

Systematic implement and the stratification induced can make it

efficient, if the variable by which the list is ordered is

Sampling
correlated with the variable of interest.
 When the whole lot is embraces a number of distinct
categories, the frame can be organized by these categories
into separate "strata."

Each stratum is then sampled as an independent subset,

out of which individual elements can be randomly selected.
The ratio of the size of this random selection (or sample) to
the size of the whole lot is called a sampling fraction.

Finally, since each stratum is treated as an independent set,

different sampling approaches can be applied to different

Stratified strata.

Sampling
 Cluster sampling increases the variability of sample estimates of
simple random sampling, depending on how the clusters differ
between one another as compared to the within-cluster
variation. Because of this reason, cluster sampling requires a
larger sample than simple random sampling to achieve the
same level of accuracy. Cluster sampling is a cheaper option.

Cluster sampling is commonly implemented as multistage

sampling.

This is a complex form of cluster sampling in which two or more

levels of units are embedded one in the other.

Cluster
The first stage consists of constructing the clusters that will be
used to sample from. In the second stage, a sample of primary
units is randomly selected from each cluster. All ultimate units

Sampling (individuals, for instance) selected at the last step of this

procedure are then surveyed. This technique, thus, is essentially
the process of taking random subsamples of preceding random
samples.
 AQL‘ stands for ‘Acceptance Quality Limit.
It is defined as the quality level that is the
worst tolerable in ISO 2859-1.

It represents the maximum number of

defective units, beyond which a batch is
rejected.

AQL
Importers usually set different AQLs for
critical, major, and minor defects.

Goods in a sample are tested in random, and

number of defective items is predetermined
amount that product is said to meet the
acceptable quantity level.

AQL sampling differ from product to product.

Products that might cause more of a health
risk will have a higher AQL.
A
Q
L

T
A
B
L
E
Components of AQL table
Lot or Batch size - This means total how many pieces inspector is going to check or inspect..
Example- If you have been offered a shipment of 400 pieces order quantity, the batch size of
this shipment will fall under 251 to 500 pieces (Code-H).

Sample size Code letter - This code is indicative of a range of batch size.
Example- Code 'L' means your lot size range is from 3201 pieces to 10000 pieces.

Sample size - It means that how many pieces will be picked up for shipment inspection from
the total offered pieces (Batch).

Ac (Accepted) - The number in this column denotes that if the inspector finds up to that
much defective pieces the shipment will be accepted by the buyer.

Re (Rejected) - On the other hand number in this column denotes that if the inspector finds
that many defective pieces or more than the listed number, the shipment will be rejected (or
asked the manufacturer for 100% inspection and re-offer for final inspection) by the buyer.
 How to Suppose we have been offered a shipment
of 500 pieces for inspection.Select the range

read AQL
from the table, it is 251-500. Now from the
AQL table, we need to select the number of
samples we are going to actually inspect.

Table?
According to the above AQL chart, we need
to select 50 pieces out of 500 pieces. Now
assume that we are inspecting at 2.5 AQL. So,
after inspecting all 50 pieces if we found 3 or
less than 3 defective pieces, we need to
accept the shipment. And if we find 4 or
more than 4 defective pieces in 50 samples,
we ned to reject that shipment.
Total number of pieces are 500 and assume
that AQL is 2.5

Lot or Batch size - 251-500

Sample size Code letter - Code 'H'

Sample size - 50

Ac (Accepted) - Lot will be accepted if

number of defects are less than or equal to 3.

Re (Rejected) - Lot will be rejected if number

of defects are equal to or more than 4.
 Items of destructive nature during inspection
01
can be inspected by sampling only.

Economy of time and money in comparison to

02
100% inspection.

Problem of inspection fatigue occurring in

03
100% inspection is eliminated.

04 Small inspection staff required.

Due to quick inspection, scheduling and

Benefits of
05
delivery times are improved.

AQL
Can exert more effective pressure on quality
06
improvement than the rejection of individual
items.
 NORMAL INSPECTION PLAN-
Sampling plan for normal inspection
01 are those inspection in Table 1 and 1A.
These plan shall be used except when
the history of inspection permits
reduced inspection or require
tightened inspection.

TIGHTENED INSPECTION PLAN-

Sampling plan for those
02 inspection are those inspection
in Table 2 and 2A.

INSPECTION REDUCED INSPECTION PLAN-

Sampling plan for those

PLAN 03 inspection are those inspection

in Table 3 and 3A.
   Special inspection levels are organized similarly to general

Special inspection levels in the AQL chart. And like general inspection
levels, their sample sizes are determined by the lot size and

Inspection
range from small (“S1”) to large (“S4”).

The main difference between general and special inspection

Level levels is that special inspection levels   generally point to much

smaller sample sizes.  The typical sample size for a special
inspection level is just a handful of pieces.  

These sample sizes are smaller because special inspection levels

are typically reserved for on-site product tests.

The Special inspection level of the AQL table is applied by the

inspector when checking the products manufactured with
respect to the customer’s other requirements. It includes the
product measurements and weights, packaging, labeling and
more, as well as all the in-site tests.
Inspection Level

Single Inspection Double Inspection Multiple Inspection

Level Level Level
 In Single Inspection Level a single sample of
size n is drawn from a lot of size N, and the
lot is accepted if the number of defectives in

Single the lot is less than the specification.

Inspection
Assurance an AQL of 2.5 % and a lot size of
1200 garments and the sample size is
80 garments. If the number of

Level
defective garments found is 5 the
total lot is "Acceptable" suppose if the
defective garments found is 6, the
total lot is "Reject/ Re-Check".
 This type of scheme is more
economical than single sampling
scheme when the quality of
incoming goods is high. Here
sample is drawn in two stages.

Double
The second sample is drawn only
when clear cut decision cannot
be drawn from the first sample.

Inspection Assurance an AQL 4.0% and a

lot size is 1200 garments and the sample size

Level is 80 garments. If the Number of defective

garments found is 7, the total lot is
"Acceptable" suppose if the defective
garments found is 8 the total lot is "Reject/ Re-
Check".
   This is an extension of the double sampling
plans where more than two samples are
needed to reach a conclusion. The advantage
of multiple sampling is smaller sample sizes.

Multiple
At each stage of sampling, the cumulated
results are analysed to take a decision of
accepting or rejecting a lot. If at any stage no

Inspection
final decision can be taken, then another
sample is drawn to take further decision. The
scheme helps in reducing the size of

Level inspection to maintain a given level of

protection.
 Switching
Procedure of
Inspection
Levels
 NORMAL TO REDUCED
When normal inspection is in effect, reduced inspection  shall  be instituted
providing that reduced inspection is considered desirable by
the  Administrator  and further provided that all of the following  conditions  are
satisfied for each class of defect:

(i)  The preceding 10 inspection lots which have been inspected within the
preceding 6 months have been on normal inspection and none has been rejected
on original inspection.
(ii)  The total number of  defects  in the  samples  from the preceding 10 inspection
lots is equal to or less than the applicable number given in Table III-B. If a double
sampling  plan is used, all  samples  inspected  should  be included, not
“first” samples only.
 REDUCED TO NORMAL

When When reduced inspection is in effect, normal inspection shall be reinstituted

if any of the following occur:

(i) An inspection lot is rejected on original inspection; or

(ii) Production becomes irregular (delayed or accelerated); or

(iii) Other valid conditions warrant that normal inspection shall be reinstituted.

 NORMAL TIGHTENED
TO TO
TIGHTENED NORMAL
  When normal inspection is in effect, When tightened inspection is in
tightened inspection  shall  be effect, normal inspection  shall  be re
instituted when 2 out of 5 consecutive instituted when five consecutive
inspection lots have been rejected on inspection lots have been considered
original inspection. acceptable on original inspection.