Final Inspection for Finished Garments: AQL Protocol.
A technical guide to Final Random Inspection (FRI) - applying ANSI/ASQ Z1.4 AQL sampling tables, visual defect classifications, POM measurement audits, and packaging checks.
General industry knowledge • Reviewed by Fenalt editorial team
Final Random Inspection is the last line of defense before apparel leaves the factory warehouse.
Final Random Inspection (FRI) protects fashion brands from receiving defective shipments. Conducted in the factory warehouse when at least 80% of an order is packed in master cartons, FRI applies international ANSI/ASQ Z1.4 statistical sampling to verify fit, stitching, trim accuracy, needle detection, and barcode labeling.
Audit Workflow
6 Stages of Final Pre-Shipment Inspection
1. 100% Production Completion & 80%+ Packed Warehouse Audit
Final Random Inspection (FRI) takes place in the factory warehouse only when 100% of the bulk order is finished and at least 80% is packed into final master export cartons.
2. Random Statistical Carton Sampling (ANSI/ASQ Z1.4)
Auditors pull sample cartons randomly from the top, middle, and bottom of warehouse pallets across all sizes according to statistical AQL tables (e.g. 125 units sampled for a 3,000-unit lot).
3. Flat Table POM Measurement & Symmetry Audit
Auditors measure sample garments flat on smooth inspection tables, logging key POM dimensions against the approved tech pack size spec table under defined tolerance limits (±1.0cm).
4. Visual Workmanship Defect Classification
Auditing samples for Critical (safety hazards like broken needles), Major (functional defects like open seams or holes), and Minor (cosmetic flaws like loose threads) defect limits.
5. Conveyor Needle & Ferrous Metal Detection Check
Verifying that 100% of packed polybags pass through calibrated needle detection scanning machines to ensure zero metal contamination.
6. Master Carton Packaging & Barcode Verification
Inspecting master carton gross weight, polybag suffocation warning prints, size ratio stickers, shipping marks, and EAN/UPC barcode scannability.
AQL Sampling Reference
ANSI/ASQ Z1.4 AQL 2.5 Sampling Pass/Fail Matrix
| Order Lot Size | AQL Sample Size | Major Defects (AQL 2.5) | Minor Defects (AQL 4.0) |
|---|---|---|---|
| 500 – 1,200 Units | 80 Garments | 5 (Pass) / 6 (Fail) | 7 (Pass) / 8 (Fail) |
| 1,201 – 3,200 Units | 125 Garments | 7 (Pass) / 8 (Fail) | 10 (Pass) / 11 (Fail) |
| 3,201 – 10,000 Units | 200 Garments | 10 (Pass) / 11 (Fail) | 14 (Pass) / 15 (Fail) |
Questions
Frequently Asked Questions
What happens if a Final Random Inspection (FRI) fails?
If major or critical defect counts exceed allowed AQL thresholds, the auditor issues a 'REJECTED' inspection report. The factory must unpack 100% of export cartons, re-screen and repair defective garments, and re-submit the lot for a second FRI audit at factory expense.
Who performs the Final Random Inspection prior to export?
FRIs are performed by independent third-party QC inspection agencies (such as SGS, QIMA, or Bureau Veritas) or by Fenalt's dedicated quality engineering team in Dhaka.
Why must 80% of garments be packed before an FRI can begin?
Inspecting packed cartons ensures auditors can evaluate export packaging, master carton labeling, polybag warning copy, and barcode scannability alongside physical garment quality.
What is an inspection Certificate of Conformance (CoC)?
A Certificate of Conformance is the official document issued after a shipment passes FRI audit under AQL 2.5 standards, authorizing the freight forwarder to release cargo for export shipping.
How long does a typical Final Random Inspection take?
A standard FRI audit sampling 125 to 200 garments takes 1 full working day for a qualified QC auditor, including measurement logging, visual auditing, and report generation.
How does Fenalt execute final inspections in Bangladesh?
Fenalt's Dhaka quality engineers conduct on-site FRI audits under ANSI/ASQ Z1.4 AQL 2.5 standards - issuing detailed photo inspection reports before releasing shipping authorization.
Independent final pre-shipment inspections
Fenalt performs Final Random Inspections (FRI) under AQL 2.5 in Dhaka before releasing shipping authorization.
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