Quality & Metrology worked example

AQL Sample Size at 5.76% acceptable quality level: a worked example

Suppose acceptable quality level falls to 5.76%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate the AQL sample size for a lot from the lot size, a sampling rate tied to your inspection level, and a minimum sample.

The inputs for this scenario

  • Inspection lot size: 1,200 parts (held at the documented default)
  • Acceptable Quality Level (AQL): 5.76 % (the input this scenario stresses; the baseline uses 8)
  • Minimum sample size: 80 parts (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Calculated sample = lot size × sampling rate.
  • Required sample size works out to 80 samples at these inputs, and this is the headline figure for the scenario.
  • Calculated sample works out to 70 samples at these inputs.
  • Minimum sample size works out to 80 samples at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where acceptable quality level sits at 8% and the headline result is 96 samples, this scenario comes in 16.67% below the baseline at 80 samples.
  • It computes the required inspection sample size by taking the larger of (lot size x sampling rate) and your stated minimum sample size. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Required sample size: 80 samples (headline result)
  • Calculated sample: 70 samples
  • Minimum sample size: 80 samples

Run it with your numbers

  • To rerun this with your own numbers, open the live AQL Sample Size calculator, set acceptable quality level to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.