Critical, major and minor defects: how they are classified in an inspection

When you receive an inspection report, you will see the defects split into three categories: critical, major and minor. This classification, based on the ISO 2859 standard and the AQL tables, is what determines whether a batch is accepted or rejected. Understanding it is key to neither accepting the unacceptable nor rejecting over trifles.

Critical defect

This is the most serious: it compromises user safety or breaches a mandatory regulation.

• Examples: sharp edges on a children's toy, electrical risk, a missing mandatory marking.
• Usual tolerance: AQL 0, that is, zero tolerance. A single critical defect is usually enough to reject the batch.

Major defect

It affects the function or usability of the product. It is not dangerous, but an end customer would probably return it.

• Examples: a zip that does not close, a motor that does not start, a seam that comes apart.
• Usual tolerance: AQL 2.5 for general consumer products.

Minor defect

It is a cosmetic imperfection or a small deviation that does not affect use and that most customers would not even notice.

• Examples: a slight colour variation, a small scratch, a loose thread.
• Usual tolerance: AQL 4.

How it translates into a decision

The inspector takes a random sample according to the batch size and the inspection level (usually General Level II). They count the defects of each type and compare them with the maximum number allowed by the AQL tables. If the defects exceed the limit of any category, the batch is rejected.

Agree it before, not after

The AQL levels must be agreed with the supplier before manufacturing and reflected in the spec sheet. If you wait until the inspection to discuss what is acceptable, you are too late.

With R'S WARE, these procedures are easier

Interpreting an AQL report and deciding whether to stand up to the factory or accept the batch takes experience. At R'S WARE we define with you the AQL levels suited to your product, carry out the inspection with clear criteria and explain the report in plain language: what was found, what it means and what we recommend you do. We negotiate with the factory on your behalf when a batch does not comply.