Acceptance Number.

The acceptance number is the maximum number of defects or defective units in the sample that will permit acceptance lot or batch. AQL has two different definitions due to standard changes. MIL-STD-105E, ISO 2859-1 (1999) Acceptable Quality Level. The acceptable level (AQL) is defined as the maximum percent defective (or the maximum number of defects per hundred units) that, for purpose of sampling inspection, can be considered satisfactory as a process average. The sampling plans most frequently used by the department of Defense are based on the AQL. ANSI/ASQC Z1.4-2003 Acceptance Quality Limit. The AQL is the quality level that is the worst tolerable process average when a continuing series of lots is submitted for acceptance sampling. The following note on the meaning of AQL was introduced with the ANSI/ASQ Z1.4-2003 revision. The concept of AQL only applies when an acceptance sampling scheme with rules for switching between normal, tightened and reduced inspection and discontinuance of sampling inspection is used. These rules are designed to encourage suppliers to have process averages consistently better than the AQL. If suppliers fail to do so, there is a high probability of being switched from normal inspection to tightened inspection where lot acceptance becomes more difficult. Once on tightened inspection, unless corrective action is taken to improve product quality, it is very likely that the rule requiring discontinuance of sampling inspection will be invoked. Although individual lots with quality as bad as the AQL can be accepted with fairly high probability, the designation of an AQL does not suggest that this is necessarily a desirable quality level. The AQL is a parameter of the sampling scheme and should not be confused with a process average which describes the operating level of a manufacturing process. It is expected that the product quality level will be less than the AQL to avoid excessive non accepted lots. The AQL values are defined as percent nonconforming or defects or nonconformities per hundred units. Defects and Defectives. A defect is any nonconformance of the unit of product with the specified requirements. A defective is a unit of product which contains

one or more defects. Failure to meet requirements with respect to quality characteristics are usually described in terms of defects or defectives. Critical - A critical defect is on that judgment and experience indicate is likely to: a. result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the products; or b. prevent performance of the tactical function of a major end item. A critical defective is a unit of product that contains one or more critical defects. Major - A major defect is one, other than critical, that is likely to result in failure, or to reduce materially the usability of the unit of product for its intended purpose. A major defective is a unit of product that contains one or more major defects. Minor - A minor defect is one that is not likely to reduce materially the usability of the unit of product for its intended purpose, or is a departure from established standards having little bearing on the effective use or operation of the unit of product. A Minor defective is a unit of product that contains one or more defects. Double Sampling Plan. A double sampling plan involves sampling inspection in which the inspection of the first sample to a decision to accept, to reject or to take a second sample. The inspection of a second sample, when required, lead to a decision to accept or reject. Drawing of Samples. Basic to sampling inspection is the assurance that the sample selected from a quantity of units represents the quality of that quantity of units. Hence, the procedure used to select units from a lot must be such that it assures a sample free of bias. Expression of Nonconformance. The extent of nonconformance of product shall be expressed either in terms of percent defective or in terms of defects per hundred units (DHU). Defects per Hundred Units. The number of defects per hundred units of any given quantity units of product is one hundred times the number of defects contained therein (one or more defects being possible in any unit of product) divided by the total number of units of product, i.e.: number of defectives x 100 Defects per hundred units = number of units inspected Inspection. Inspection is the process of measuring, examining, testing, or otherwise comparing the unit of product with the requirements.

Inspection by Attribute. Inspection by attributes is inspection where by either the unit of product is classified simply as defective or non-defective, or the number of defects in the unit of product is counted, with respect to a given requirement or set of requirements. Inspection Levels. The standards provides for three general inspection levels and four special inspection levels. These seven levels permit the user to balance the cost of inspection against the amount of protection required. Lot or Batch. The term lot or batch shall mean "inspection lot" or "inspection batch" i.e., a collection of units of product from which a sample is to drawn and inspected to determine conformance with the acceptance criteria, any may differ from a collection of units designated as a lot or batch for other purposes (e.g., production, shipment, etc.). Nonconformance. Nonconformance may be defined as the failure of a unit of product to conform to specified requirements for any stated quality characteristic. The extent of nonconformance of product to the required quality characteristics shall be expressed either in terms of percent defective or in terms of defects per hundred units (DHU). Normal Inspection. Normal inspection is that which is used where there is no evidence that the quality of product being submitted is better or poorer than the specified quality level. Percent Defective. The percent defective of any given quantity of units of product is one hundred times the number of defective units of product contained therein divided by the total number of units of product, i.e.: Percent defective = number of defectives x100 / number of units inspected Reduced Inspection. Reduced inspection under a sampling plan uses the same quality level as for normal inspection, but requires a smaller sample for inspection. Rejection Number. The rejection number is the minimum number of defects or defective units in the sample that will cause rejection of the lot represented by the sample. Representative Sampling. When appropriate, the number of units in the sample shall be selected in proportion to the size of sub-lots or sub-batches, or parts or the lot or batch, identified by some rational criterion. When representative sampling is used, the units from each part of the lot or batch shall be selected at random.

Resubmitted Lots or Batches. Lots or batches found unacceptable shall be resubmitted for reinspection only after all units are re-examined or retested and all defective units are removed or defects corrected. The responsible authority shall determine whether normal or tightened inspection shall be used and whether reinspection shall include all types or classes of defects or only the particular types or classes of defects which caused initial rejection. Sample. A sample consists of one or more units of product drawn from a lot or batch, the units of the sample being selected at random without regard to their quality. The number of product in the sample is the sample size. Sampling Plans. A lot sampling plan is a statement of the sample size or sizes to be used and the associated acceptance and rejection numbers. Single Sample Plan. A single sampling plan is a type of sampling plan by which the results of a single sample from an inspection lot are conclusive in determining acceptability. The number of sample units inspected shall be equal to the sample size given by the plan. Severity of Inspection. The severity of inspection concerns the total amount, kind and extent of inspection specified by the quality assurance provisions established for the unit of product, or as dictated by quality history. Unit of Production. The unit of product is the thing inspected in order to determine its classification as defective or non-defective or to count the number of defects. It may be a single article, a pair, a set, a length, an area, an operation, a volume, a component of an end product, or the end product itself. The unit of product may or may not be the same as the unit of purchase, supply, production, or shipment. Tightened Inspection. Tightened inspection under a sampling procedure plan uses the quality level as for normal inspection, but requires more stringent acceptance criteria. Form OF Sampling With each of these major sampling plans there may be Single sampling that is , basing the acceptance or rejection of a lot upon the units in one sample drawn from that lot 2. Double sampling, that is selecting one sample of units from a lot and under certain conditions selecting a second sample before accepting or rejecting a lot 1.

3. Multiple sampling, that is basing acceptance or rejection of a lot upon the results of several samples of units drawn from that lot . Of these three methods, double sampling has probably been the most popular for reasons as the following: Double Sampling As Compared With Single Sampling 1. Psychologically the idea of giving a lot of material a second chance before rejecting it has popular appeal. Double sampling is therefore sometimes easier to sell in the factory. 2. Double sampling plans permit a smaller for sample than is called for by the sample size of the corresponding single sampling plan. When the percent non-conformance is either low or high in material submitted for inspection, it is frequently possible to accept or reject lots based upon the results of the first sample. In these instances, therefore double sampling permits lower sampling costs. Double Sampling As Compared With Multiple Sampling 1. Double-sampling plans are often easier to administer than multiple sampling plans. The need for selecting successive samples in the proper fashions may require greater administrative control and more highly skilled inspection operators. 2. In theory, multiple sampling may often permit lower total inspection than double sampling for a given degree of protection because of the smaller sample sizes required. In practice, however, the greater complexity of multiple sampling may, in some cases, return the overall cost advantage to double sampling. This is particularly true when the percent nonconformance in submitted lots is low- say,0.1 percent-in these cases, the amount of inspection required by single and double sampling plans based upon process averages is much the same for that for multiple sampling Inspite of the popularity of double sampling, there are certain benefits unique to both single and multiple sampling. Single sampling 1. Single sampling may be the only practical type of sampling plan under conveyorized production conditions when it is physically possible to select only one sample. 2. With lots of material whose percents nonconformance are close to the AQL, single sampling may offer more economical inspection protection than double sampling. 5

Multiple sampling 1. When administrative costs can be kept low, multiple sampling may permit lower inspection costs for given degrees of protection than either single or double sampling. 2. Newer methods to simplify multiple sampling, among them computer based sampling, may result in greater improved efficiency in administering these sampling plans. 3. Multiple sampling corresponds to the fashion in which an inspector normally selects samples.

The type of product and the way the product is presented for sampling-on a conveyor, in boxes piled on top of other, and so forth-are the factors that must be taken into account. Again, the choice of single, double, or multiple sampling depends upon the particular conditions for which the sampling plan is to be used. None of the three methods may be termed best; they may be merely best for certain sampling conditions. Procedure for Double Sampling Plan Find the Sample Size Code Letter Set the range covering the Batch or Lot Size being inspected in the window at the top right corner on the front of the AQL Inspector's Rule. Then read the Sample Size Code Letter, in the box, directly to the left of the Inspection Level. Find the Sampling Plan The Double Sampling Plan consists of two sets of Acceptance Numbers, Rejection Numbers and Sample Sizes. Normal inspection is used until such time as the results of inspection dictate the Tightened or Reduced inspection should be employed as outlined in Switching Procedures on page 10. Double sampling plans are found on the back of the AQL Inspector's Rule. Set the required AQL level in the window above the Double Sampling Plans. Locate the Sample Size Code Letter previously selected in step 1. If an arrow show in the window directly below the Code Letter, follow the direction of the arrow until a set of acceptance-rejection numbers are reached. Then read the first Acceptance (in black) and Rejection (in color) Number in the window on the '"1st" row. 6

The Acceptance and Rejection number pairs and the Sample Sizes directly below them make up the Sample Plan. Perform the First Inspection Randomly select a group of "Sample Size" items from the lot and inspect them. If the sample size equals or exceeds the lot size do 100% inspection. If the number of defective items is equal to or less than the Acceptance Number accept the lot. If the number of defective items is equal to or greater than the "Rejection Number" reject the lot. Perform The Second Inspection If the lot was the accepted or rejected from the first inspection the second sample inspection is not required, skip this step. Read the Acceptance and Rejection Numbers and Sample size from the "2nd" row under those used for the first inspection. Randomly select a second group of "Sample Size" items from the lot and inspection them. Combine the total number of defective items from the first and second samples. If the total number of defective items is equal to or less than the Acceptance Number accept the lot. If the total number of defective items is equal to or greater than the "Rejection Number" reject the lot.

Statistical Sampling Tables Table # B.1 Lot/Batch Size 2 to 8 9 to15 16 to 25 26 to 50 Sample Size Code Letters Sample Size Code Letter A B C D 7

51 to 90 91 to 150 151 to 280 281 to 500 501 to 1200 1201 to 3200 3201 to 10000 10001 to 35000 35001 to 150000 150001 to 500000 500001 & over (Source-MIL- STD-105)

E F G H J K L M N P Q

Table # B.2 Normal Inspection Plan: Single Sampling Acceptable Quality Levels AQL -Normal Inspection Sample Size Code Letter Sample Size 1.0 1.5 2.5 4.0 6.5 Ac Re Ac Re Ac Re Ac Re Ac Re A 2 0 1 0 1 0 1 0 1 0 1 B 3 0 1 0 1 0 1 0 1 0 1 C 5 0 1 0 1 0 1 0 1 1 2 D 8 0 1 0 1 0 1 1 2 1 2 E 13 0 1 0 1 1 2 1 2 2 3 F 20 0 1 1 2 1 2 2 3 3 4 G 32 1 2 1 2 2 3 3 4 5 6 H 50 1 2 2 3 3 4 5 6 7 8 J 80 2 3 3 4 5 6 7 8 10 11 K 125 3 4 5 6 7 8 10 11 14 15 L 200 5 6 7 8 10 11 14 15 21 22 M 315 7 8 10 11 14 15 21 22 21 22 N 500 10 11 14 15 14 15 21 22 21 22 P 800 14 15 21 22 21 22 21 22 21 22 Q 1250 21 22 21 22 21 22 21 22 21 22 (Source-MIL- STD- 105) Table # B.3 Normal Inspection Plan: Double Sampling Acceptable Quality Levels AQL -Normal Inspection 1.0 1.5 2.5 4.0 6.5

Sample Sample Sampl Cumulati Size e Size ve Code Sample Size

Ac

Re

Ac

Re

Ac

Re

Ac

Re

Ac

Re

A B C D E F G H J K L M N P Q

First Second First Second First Second First Second First Second First Second First Second First Second First Second First Second First Second First Second First Second First Second First Second 2 2 3 3 5 5 8 8 13 13 20 20 32 32 50 50 80 80 125 125 200 200 315 315 500 500 800 800 2 4 3 6 5 10 8 16 13 26 20 40 32 64 50 100 80 160 125 250 200 400 315 630 500 1000 800 1600

0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 3 1 4 2 6 3 8 5 12 7 18 11 26

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 3 4 4 5 5 7 7 9 9 13 11 19 16 27

0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 3 1 4 2 6 3 8 5 12 7 18 11 26 11 26

1 1 1 1 1 1 1 1 1 1 2 2 2 2 3 4 4 5 5 7 7 9 9 13 11 19 16 27 16 27

0 0 0 0 0 0 0 0 0 1 0 1 0 3 1 4 2 6 3 8 5 12 7 18 11 26 11 26 11 26

1 1 1 1 1 1 1 1 2 2 2 2 3 4 4 5 5 7 7 9 9 13 11 19 16 27 16 27 16 27

0 0 0 0 0 0 0 1 0 1 0 3 1 4 2 6 3 8 5 12 7 18 11 26 11 26 11 26 11 26

1 1 1 1 1 1 2 2 2 2 3 4 4 5 5 7 7 9 9 13 11 19 16 27 16 27 16 27 16 27

0 0 0 0 0 1 0 1 0 3 1 4 2 6 3 8 5 12 7 18 11 26 11 26 11 26 11 26 11 26

1 1 1 1 2 2 2 2 3 4 4 5 5 7 7 9 9 13 11 19 16 27 16 27 16 27 16 27 16 27

(Source-MIL- STD-105) Normal, reduced, and tightened inspection The standard form of, many sampling tables is generally called normaltables. Many well conceived acceptance-sampling procedures,

such as MIL-STD-105D, also provide for reduced sampling and in some cases tightened sampling plans for use to supplant normal sampling under certain circumstances. This is provided for in what is called the switching rule of the plan in technical sampling terms. When, for example, the quality of lots submitted for inspection is consistently better than the specified quality index value, which may be demonstrated by the fact that no lots are being rejected then a reduced sampling schedule may be used in place of normal sampling under certain acceptance plans. These reduced schedules are usually similar in form to the normal schedules, except that the first sample sizes , which correspond to a given lot size, are smaller. Such tables may have for example a first reduced sample one-fifth the size of the first normal sample. Reduced sampling permits a decrease in inspection cost. This type of sampling can be continued until the quality of the material were to become poorer and call for returns to normal sampling. When the quality of lots submitted for inspection is consistently poorer than the quality target aimed for, a tightened sampling schedule is called for. This tightened schedule is usually similar to the normal schedule, except that the allowable number of defectives for a given sample size is reduced. When tightened inspection is in effect, normal inspection should be instituted when 5 consecutive lots or batches have been considered acceptable and original inspection. After tightened inspection has been in effect for 10 consecutive lots, sampling inspection under the standard is terminated until action is taken to improve the process. Acceptance criteria under tightened inspection

Code letter E H K N

normal n 13 50 125 500 c 0 1 3 10

tightened n 20 80 125 500 c 0 1 2 8

10

In the first three cases the criteria under tightened inspection for a 1% AQL are the same as the criteria under normal inspection for the stated code letter for the next lower AQL, namely , .65% . in most cases in the ABC standard , the tightened criteria are identical with the normal criteria for the next lower AQL class, although there are a number of exceptions. Criteria for qualification and loss of qualification for reduced inspection Generally speaking, eligibility for reduced inspection should be based on recent quality history indicating average quality considerably better than the AQL. Moreover, it should seem likely that the product to be inspected under reduced inspection will be produced under the same conditions that gave rise to the recent good quality history. The ABC standard states the following conditions for a shift from normal to reduced inspection : The preceding 10 lots or batches (or more,) have been on normal inspection and none has been rejected on original inspection; and The total number of the defectives (or defects ) in the samples from the preceding 10 lots or batches (or such other number as was used for conditions a above ) is equal to or less than the applicable number given in table 16. If double or multiple sampling is in use , all samples inspected should be included , not firstsamples only; and Production is a steady rate ; and Reduced inspection is considered desirable by the responsible authority.

Normal inspection must be reinstated whenever a lot or batch is rejected or production becomes irregular or delayed, or other conditions warrant that normal inspection shall be instituted. Acceptance criteria under reduced inspection In all the military AQL systems using sample size code letters, the code letter in reduced inspection has been determined just as in normal inspection.. The relationship between the criteria under normal and reduced inspection may be illustrated with reference to the single sampling normal plans for a 1% . Code letter E Normal n 13 accept 0 reduced reject n 1 5 accep t 0 reject 1

11

H K N

50

2 4 11

20 50 200

0 1 5

2 4 8

125 3 500 10

It is clear that the acceptance criteria shown for code letters H, K, and N under reduced inspection all have an area of indecision in which the lot is neither accepted nor rejected. The standard states that, whenever the number of defectives falls in this indecision region (for example, if there should be exactly 1 defective in the sample of 20 with code letter H), the lot in question shall be accepted but reduced inspection shall be continued and normal inspection reinstated. General comments on reduced inspection in acceptance/rejection plans A provision for reduced inspection is not a necessary part of an acceptance/rejection plan. Nevertheless, such a provision is based on a principle that is economically sound. The principle is to concentrate inspection on those products and quality characteristics where the quality history is doubtful and to give less attention where the quality history is very good. The consumers savings in inspection costs under reduced inspection are apparent. The producers advantages are not quite so obvious. However, because the acceptance criteria in reduced inspection are not so stringent, the producer receives added protection against lot rejection. The producer may also have a real sense of accomplishment in having qualified for reduced inspection. Hence, from the consumers point of view point, the provisions for reduced inspection in any acceptance program may provide a useful nonfinancial incentive to the producer to improve quality.

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