garment-aql-calculator

AQL (Acceptable Quality Limit) sampling calculator for garment industry quality control. Implements ISO 2859-1 — the universal standard for inspection by attributes used by every garment QC team globally.

Built and used in production by Scan ERP — a garment manufacturing ERP running on a 100+ machine CMT factory in Nepal. See the live AQL lookup tool →

Install

npm install garment-aql-calculator

Why this exists

Every garment factory QC team runs AQL sampling on every shipment. Existing tools (QIMA, HQTS, Tetra Inspection) are web-only — no programmatic library. This package fills that gap so ERP systems, QC apps, and custom dashboards can run AQL calculations natively.

Quick start

const { calculateAQL } = require('garment-aql-calculator');

const result = calculateAQL({
  lotSize: 2400,
  inspectionLevel: 'GII',
  aql: 2.5,
});

console.log(result);
// {
//   lotSize: 2400,
//   inspectionLevel: 'GII',
//   aql: 2.5,
//   codeLetter: 'K',
//   sampleSize: 125,
//   acceptNumber: 7,
//   rejectNumber: 8,
//   decision: [Function]
// }

// Use the decision function with actual defects found
console.log(result.decision(5));   // 'ACCEPT' (5 ≤ 7)
console.log(result.decision(8));   // 'REJECT' (8 ≥ 8)

Full garment inspection (critical + major + minor)

Standard garment QC runs three AQL sampling plans simultaneously. Use the convenience function:

const { calculateGarmentInspection } = require('garment-aql-calculator');

const inspection = calculateGarmentInspection({
  lotSize: 2400,
  inspectionLevel: 'GII',
  // Defaults — standard garment industry values
  criticalAQL: 0.65,
  majorAQL: 2.5,
  minorAQL: 4.0,
});

console.log('Critical:', inspection.critical.sampleSize, 'accept', inspection.critical.acceptNumber);
console.log('Major:',    inspection.major.sampleSize,    'accept', inspection.major.acceptNumber);
console.log('Minor:',    inspection.minor.sampleSize,    'accept', inspection.minor.acceptNumber);

API

calculateAQL({ lotSize, inspectionLevel, aql })

Param	Type	Default	Notes
lotSize	number	required	Total units in the production lot (≥ 2)
inspectionLevel	string	'GII'	One of S1, S2, S3, S4, GI, GII, GIII
aql	number	2.5	One of 0.65, 1.0, 1.5, 2.5, 4.0, 6.5

Returns { codeLetter, sampleSize, acceptNumber, rejectNumber, decision }.

calculateGarmentInspection({ lotSize, inspectionLevel, criticalAQL, majorAQL, minorAQL })

Returns three AQL results — one for each defect tier.

getCodeLetter(lotSize, inspectionLevel)

Lower-level utility: returns just the ISO 2859 code letter.

ISO 2859 reference

Inspection level	Use case
GI	Lower-risk products, smaller sample
GII	Default — most garment inspections
GIII	Higher-risk products, larger sample
S1, S2, S3, S4	Special inspection levels for destructive or expensive testing

Garment defect tier	Standard AQL
Critical (safety, regulatory)	0.65
Major (workmanship affecting function)	2.5
Minor (cosmetic only)	4.0

Try Scan ERP

This calculator is free. The full ERP system that uses it daily — QR-based bundle tracking, automated piece-rate payments, live WIP dashboards, factory hardware integration — is at scanerp.pro.

• Live demo · 1.4M+ pieces tracked in production
• AQL sample-size lookup tool (uses this library under the hood)
• Free 30-day trial · No credit card
• WhatsApp: +977-9863618347

License

MIT — © 2026 Santosh Rijal / Scan ERP

Related packages

• garment-smv-calculator — SMV/SAM time-study
• garment-piece-rate — Piece-rate payment calculation
• garment-bundle-id — Bundle ID generation
• garment-dhu-calculator — Defects Per Hundred Units
• garment-line-efficiency — Sewing line efficiency
• garment-fabric-consumption — Fabric consumption
• garment-cmt-cost — CMT cost calculation

Related Packages — Scan ERP Garment Toolkit

Part of the Scan ERP open-source garment toolkit — production-tested utilities for CMT factory operations, all MIT licensed:

• aql-sample-size — ISO 2859-1 sample-size lookup (zero-dependency data library)
• garment-aql-calculator — Full AQL inspection decision engine with pass/fail logic
• garment-bundle-id — Bundle QR code generator + parser (STYLE-LOT-COLOR-SIZE-BUNDLE# format)
• garment-cmt-cost — CMT cost calculator with 13-country CPM comparison
• garment-dhu-calculator — Defects Per Hundred Units with defect-type breakdown + multi-checker aggregation
• garment-fabric-consumption — Fabric consumption (knit GSM × area, woven marker length)
• garment-line-efficiency — Line efficiency, target output, line balance / bottleneck detection
• garment-piece-rate — Piece-rate earnings calculator with bonuses and overtime
• garment-smv-calculator — Stopwatch SMV/SAM with Westinghouse performance rating

See the curated awesome-garment-erp list for the full Scan ERP ecosystem, or visit scanerp.pro for the production garment manufacturing ERP this toolkit powers.