Acceptance Sampling

System
by
Attributes
Assoc. Prof. Ir. Dr. Cheong Kuan Yew
School of Materials & Mineral Resources Engineering
Engineering Campus
Universiti Sains Malaysia
 Topic Outcome:
At the end of this topic, students will be able to:
 Use sampling system for lot-by-lot
sampling (ANSI/ASQ Z1.4 1993 & Dodge-
Romig sampling Tables)
 Use sampling system for isolated lot sampling
(ANSI/ASQ Standard Q3 – 1998)
 Topic Outline:
• Lot-by-lot Acceptance Sampling Plans:
1)AQL Sampling Plans (ANSI/ASQ Z1.4 1993)
- An Introduction.
- Inspection Level
- Types of Sampling Plans.
- Switching Procedures
- AOQL factors
- LQ
- ASN
• Isolated lot Acceptance Sampling Plan
ANSI/ASQ Standard Q3
- 1998
 Refresh:
• Sampling plan, scheme, & system
Lot-by-lot Acceptance
Sampling Plans
AQL Sampling Plans – ANSI/ASQ Z1.4 – 1993
LQ Sampling Plans Dodge-Romig
AOQL Sampling Plans Sampling Tables
ANSI/ASQ Z1.4 – 1993
 An Introduction
 ANSI/ASQ Z1.4 – 1993
 ASQ = American Society for Quality
 A sampling plan for lot-by-lot inspection by attributes for
use by US government & industries
1942 (@Bell Telephone Lab) – JAN-STD-105
Since that time, there have been 5 revisions (MIL-
STD-105E).
1973 – adopted by ISO (International Organization for
Standardization) and designated International Standard
ISO/DIS-2859.
1993 – modifications were made by ASQ under
designation ANSI/ASQ Z1.4  all tables and
procedures remain unchanged, but with 3 basic
changes:
 ANSI/ASQ Z1.4 – 1993

1) Nonconformity (tak kesesuaian) and

nonconforming (tak sesuai) unit are substituted for
the words defect (cacat) and defective (kecacatan).

2) The switching rule that used a limit number for

one of the reduced inspection criteria is an option.

3) Additional tables for AOQL,LQ,ASN,and OC

curves are added. These tables reflect scheme
performance, which is the combination of switching
among normal, tightened, and reduced sampling
plans.
 The most widely used acceptance sampling plan in
the world.
 Quality Index is AQL.

 In Malaysia  Malaysian Standard, MS 567: Part 1

& 2 – 1978.
 Inspection Level

 Inspection level determines

relationship between lot size (N) and
sample size (n).
 The levels of inspection offered are (Table 1: Sample size
code letters (abjad)):
Level II – Normal Level, designated as N.

Level III – Tightened Level (tahap diperketat), designated as T.

Greater discrimination is required. Introduced when

there is deterioration of process capability.

Level I – Reduced Level (tahap dipermudah), designated as R.

Less discrimination is required. Introduced when there

is an improvement of process capability or no rejected
lots for a specified period.
 4 additional special levels are given in the same table:
S-1
S-2
S-3
S-4
 May be used where relatively small sample sizes are
necessary and large sampling risks can be tolerated.
 Types of Sampling Plans

 This Standard offers:

Single Sampling Plans
Double Sampling Plans
Multiple Sampling Plans
 Single Sampling Plans
Only a number of sample is taken per plan.
 Double Sampling Plans
An initial sample is taken.
Based on the information, a decision is made to
A) Accept the lot,
B) Reject the lot, or
C) Take a second sample.
If the 2nd sample is taken, the information from 1st
and 2nd is combined to reach a decision to accept or
reject the lot.
 Multiple Sampling Plans
This is an extension of the double sampling
concept.
More than 2 samples are drawn to reach a
decision either to reject or accept the lot.
 Summary of Advantages & Disadvantages of
Various Types of Sampling Plans

SINGLE DOUBLE MULTIPLE

Acceptability to One chance to Better chance to

Indecisive
Producer pass pass
10% to 50% 30% less than
Number to be
Greatest less than Single Double
Inspected
Sampling Plans Sampling Plans

Cost Lowest Fair Greatest

Information Most Less Least

Simplicity Easiest Hard Hardest

Estimation of
Good Fair Fair
Quality
 How to use this Standard for Single Sampling
Plans?
 The steps are:
1) Decide on AQL.
2) Decide on the inspection level.
3) Decide on the type sampling plan to be used 
SINGLE
4) Decide whether normal, tightened, or reduced
inspection is to be used.
5) Determine Lot size (N).
6) Use Table 1 to find the sample size code letter.
7) Use the appropriate table to obtain the plan (Table
II.A to II.C).
8) Look at OC curve.
Q&A

1) Determine a single sampling plan if AQL = 1.0%, the

inspection level is II and the Lot size is 2500.

Table 1- Sample size code letter  K

Table II.A – Single sampling plans for normal inspection
(Master table)  n=125, Ac=3, Re=4.
Q&A

2) Determine a single sampling plan if AQL = 0.4%, the

inspection level is I and the Lot size is 230.

3) Determine a single sampling plan if AQL = 0.015%, the

inspection level is III and the Lot size is 120.

4) Determine a single sampling plan if AQL = 0.65%, the

inspection level is II and the Lot size is 6000.

5) Determine a single sampling plan if AQL = 0.4%, the

inspection level is II and the Lot size is 250.
 Switching Procedures

 This standard has provision for switching of sampling

plan to a tighter sampling plan when the supplier’s (or
producer’s) quality has deteriorated.
 It is also provides for a switch to reduced inspection
when the product quality has improved.
NORMAL to TIGHTENED
Tightened inspection is instituted where 2 out of 5
consecutive lots have been rejected on original
inspection.
TIGHTENED to NORMAL
When tightened inspection is in effect, normal
inspection shall be reinstated when 5 consecutive lots
have been accepted on original inspection.
NORMAL to REDUCED
To qualify for reduced inspection, the following
conditions must be satisfied:

10 consecutive lots have been accepted on

normal and original inspection.

The total number of nonconforming in the 10

samples is equal or less than the limit number.

Production is at steady state.

Reduced inspection is considered desired by

inspecting authority.
REDUCED to NORMAL
When reduced inspection is in effect,normal inspection
is reinstated when:
A lot is rejected.
Sampling terminates without either
acceptance or rejection criteria having been
met. The lot is considered acceptable but
normal inspection is reinstated.
Production becomes irregular or delayed.
Other conditions warrant that normal
inspection shall be re-instated.
 Summary of Switching Rules

• Preceding 10 lots START • 2 out of 5

Accepted with total
nonconforming less than consecutive
limit number, lots not
• Steady production, and accepted
• Approval from
responsible authority.

NORMAL TIGHTENED
REDUCED

• Lot not accepted, or • 5 consecutive

• Lot accepted but lots accepted
nonconformities found
lie between Ac and Re • 10 consecutive lots
of the plan, or
Remain on Tightened
• Irregular production, or
• Other conditions
warrant.
• Discontinue
inspection
 How to use this Standard for Double Sampling
Plans?
 Schematic Operation of a Double Sampling.

Inspect a 1st sample of n1 pieces

If the number of nonconforming

found in the 1st sample
Does not exceed c1 Exceeds c1, but does Exceed r1
not exceed r1

Inspect a 2nd sample of n2 pieces

Accept the Lot Reject the Lot
If the number of nonconforming found in
the 1st and 2nd samples combined

Does not exceed c2 Equal or exceed r2

 The steps are:
1) Decide on AQL.
2) Decide on the inspection level.
3) Decide on the type sampling plan to be used 
DOUBLE
4) Decide whether normal, tightened, or reduced
inspection is to be used.
5) Determine Lot size (N).
6) Use Table 1 to find the sample size code letter.
7) Use the appropriate table to obtain the plan (Table
III.A to III.C).
8) Look at OC curve.
 Q&A

1) Determine a double sampling plan if AQL = 1.0%, the

inspection level is II and the Lot size is 2500.

Table 1- Sample size code letter  K

Table III.A – Double sampling plans for normal inspection
(Master table)  n1=80, cumulative sample size=80
 n2=80, cumulative sample size=160

AQL=1.0%

Ac Re

First 1 4
Second 4 5
Q&A

2) Determine a double sampling plan if AQL = 0.4%, the

inspection level is I and the Lot size is 230.

3) Determine a double sampling plan if AQL = 0.015%,

the inspection level is III and the Lot size is 120.

4) Determine a double sampling plan if AQL = 0.65%, the

inspection level is II and the Lot size is 6000.

5) Determine a double sampling plan if AQL = 0.4%, the

inspection level is II and the Lot size is 250.
 How to use this Standard for Multiple Sampling
Plans?

 Schematic Operation of a Multiple Sampling.

 Inspect a 1st sample of n1 pieces

If the number of nonconforming

found in the 1st sample
Does not exceed c1 Exceeds c1, but does not Exceed r1
equal or exceed r1

Inspect a 2nd sample of n2 pieces Do not

Accept the Lot Accept
If the total number of nonconforming the Lot*
found in the 1st and 2nd samples
combined
Does not Equal or
exceed c2 Exceeds c2, but does not exceed r2
equal or exceed r2
 Inspect a 3rd sample of n3 pieces

If the total number of nonconforming

found in the first three samples
combined
Does not Equal or
Exceeds c3, but does not
exceed c3 exceed r3
equal or exceed r3

Accept the Lot Do not Accept the Lot*

Etc.

* Some of these plans continue to the ‘bitter end’, i.e., the taking of
samples continues if necessary until the lot is fully inspected, unless
the plan has meanwhile ‘made up its mind’.
 The steps are:
1) Decide on AQL.
2) Decide on the inspection level.
3) Decide on the type sampling plan to be used 
MULTIPLE
4) Decide whether normal, tightened, or reduced
inspection is to be used.
5) Determine Lot size (N).
6) Use Table 1 to find the sample size code letter.
7) Use the appropriate table to obtain the plan (Table
IV.A to IV.C).
8) Look at OC curve.
Q&A

1) Determine a multiple sampling plan if AQL = 1.0%, the

inspection level is II and the Lot size is 2500.
Table 1- Sample size code letter  K
Table IV.A – Multiple sampling plans for normal
inspection (Master table)
sample Sample size Cumulative AQL=1.0%
sample size
Ac Re

First 32 32 # 3
Second 32 64 0 3
Third 32 128 1 4
Fourth 32 160 2 5

# acceptance not permitted at this sample size.

Q&A

2) Determine a multiple sampling plan if AQL = 0.4%, the

inspection level is I and the Lot size is 230.

3) Determine a multiple sampling plan if AQL = 0.015%,

the inspection level is III and the Lot size is 120.

4) Determine a multiple sampling plan if AQL = 0.65%, the

inspection level is II and the Lot size is 6000.

5) Determine a multiple sampling plan if AQL = 0.4%, the

inspection level is II and the Lot size is 250.
 Average outgoing quality limit factors
 Tables V-A and V-B.

Limiting Quality (LQ)

 Tables VI-A and VI-B. (for consumer’s risk of 0.10)
 Tables VII-A and VII-B (for consumer’s risk of 0.05)
 A sampling plan for isolated lots can be obtained that will
come close to both the producers’ and consumers’ criteria.
 It is much easier to use ANSI/ASQ standard Q3 – 1988.
 Table VIII. (for reduced inspection)
 Average Sample Number(ASN)
 Table IX – Average sample size curves for double and
multiple sampling.
 Assumption: no curtailment of inspection and are
approximate to Poisson distribution, and the sample size
for double and multiple sampling are assumed to be 0.631n
and 0.25n.
 Arrow indicates the location of the AQL.
ANSI/ASQ Standard Q3 - 1988
 ANSI/ASQ Standard Q3 - 1988
 It is used for inspection of isolated lots by attributes.
 It complements ANSI/ASQ Z1.4-1993 (for continuous
stream of lots).
 Indexes tables by Limiting Quality (LQ).
 1st scheme:
It is designated to be used for lots that are isolated or
mixed or that have an unknown history as far as both
vendor and vendee know.
Lot size and LQ value must be known.
Table 10-6
 Q & A:
Q: Lot size = 295, LQ=3.15%, determine the sampling
plan.
A: n=80, Ac=0
 2nd scheme:

When a vendor is producing a continuous stream of lots

and sends one or a few to a customer who will consider
them as isolated lots (purchasing of small qualities of
a raw material).
material
Example of Table for LQ=3.15%

Table 10-7
The last 5 columns can be used to plot the OC curves.
 Q & A:
Q: Lot size = 295, inspection level II, LQ=3.15%, where
the isolated lot is from a vendor with a continuous
stream of product, determine the sampling plan.
A: n=125, Ac=1
End