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Chapter 3
Acceptance Sampling

Acceptance Sampling

• Inspection of raw materials, semifinished products, or finished products is one aspect of quality
assurance.

• When inspection is for the purpose of acceptance or rejection of a product, based on adherence to
a standard, the type of inspection procedure employed is usually called acceptance sampling.

• Acceptance sampling is an important field of statistical quality control that was popularized by
Dodge and Romig and originally applied by the U.S. military to the testing of bullets during World
War II.

• The principle works in such a way that a sample should be picked at random from the lot, and on
the basis of information that was yielded by the sample, a decision should be made either to accept
or reject the lot.

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Lot Acceptance Sampling Plans

• Acceptance sampling is "the middle of the road" approach between no

inspection and 100% inspection.
• There are two major classifications of acceptance plans:
• by variables.
• by attributes ("go, no-go"), and
• Acceptance sampling is employed when one or several of the
following hold:
• Testing is destructive,
• The cost of 100% inspection is very high,
• 100% inspection takes too long.

Lot Acceptance Sampling Plans

A lot acceptance sampling plan (LASP) is a sampling scheme and a set of
rules for making decisions.
The decision, based on counting the number of defectives in a sample, can be
to accept the lot, reject the lot, or even, for multiple or sequential sampling
schemes.
LASPs fall into the following categories:
1. Single sampling plans
2. Double sampling plans
3. Multiple sampling plans
4. Sequential sampling plans
5. Skip lot Sampling Plans

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Lot Acceptance Sampling Plans

Definitions of basic Acceptance Sampling terms are as follows:

• Acceptable Quality Level (AQL): The AQL is a percent defective that
is the base line requirement for the quality of the producer's product.
• Lot Tolerance Percent Defective (LTPD): The LTPD is a designated
high defect level that would be unacceptable to the consumer.
• Type I Error (Producer's Risk): This is the probability, for a given (n,
c) sampling plan, of rejecting a lot that has a defect level equal to the
AQL. (typical values for range from 0.2 to 0.01.)
• Type II Error (Consumer's Risk): This is the probability, for a given
(n, c) sampling plan, of accepting a lot with a defect level equal to the
LTPD.

Lot Acceptance Sampling Plans

• Operating Characteristic (OC) Curve: This curve plots the lot fraction or percent
defectives (X-axis) versus the probability of accepting the lot (Y-axis).
• Average Outgoing Quality (AOQ): A common procedure, when sampling and testing is
non-destructive, is to 100% inspect rejected lots and replace all defectives with good
units.
• In AOQ , if all lots come in with a defect level of exactly p, and the OC curve for the
chosen (n, c) LASP indicates a probability Pa of accepting such a lot, over the long run
the AOQ can easily be shown to be:
P P( N  n)
AOQ  a
N
Where
N is the lot size

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Lot Acceptance Sampling Plans

• Average Outgoing Quality Level (AOQL): A plot of the AOQ (Y-axis) versus the incoming lot p
(X-axis) will start at 0 for p = 0, and return to 0 for p = 1 (where every lot is 100% inspected and
rectified). In between, it will rise to a maximum. This maximum, which is the worst possible long
term AOQ, is called the AOQL.
• Average Total Inspection (ATI): When rejected lots are 100% inspected, it is easy to calculate the
ATI if lots come consistently with a defect level of p. For a LASP (n, c) with a probability pa of
accepting a lot with defect level p, we have

ATI  n  (1  Pa )(N  n)
where
N is the lot size.

Lot Acceptance Sampling Plans

• Average Sample Number (ASN): For any given double, multiple or

sequential plan, a long term ASN can be calculated assuming all lots
come in with a defect level of p.
A plot of the ASN, versus the incoming defect level p, describes the
sampling efficiency of a given LASP scheme.

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Sampling Plans
i) Single Sampling Plan: One sample of items is selected at random from a
lot and the disposition of the lot is determined from the resulting
information. These plans are usually denoted as (n,c) plans for a sample
size n, where the lot is rejected if there are more than c defectives.

There are two widely used ways of picking (n, c):

• Use tables (such as MIL STD 105D) that focus on either the AQL or the LTPD
desired.
• Specify 2 desired points on the OC curve and solve for the (n, c) that uniquely
determines an OC curve going through these points.

Sampling Plans
a) Military Standard 105E sampling plan: Standard military sampling
procedures for inspection by attributes were developed during World
War II. After then many universities and organizations adopted it with a
little modification.
b) Military Standard 105D sampling plan: This document is essentially
a set of individual plans, organized in a system of sampling schemes.

In applying the Mil. Std. 105D it is expected that there is perfect

agreement between Producer and Consumer regarding what the AQL is
for a given product characteristic.

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Sampling Plans

The steps in the use of the standard can be summarized as follows:

• Decide on the AQL.
• Decide on the inspection level.
• Determine the lot size.
• Enter the table to find sample size code letter.
• Decide on type of sampling to be used.
• Enter proper table to find the plan to be used.
• Begin with normal inspection; follow the switching rules and the rule for stopping the
inspection (if needed).

Example
• A manufacturer needs to inspect a lot of 2,500 units using MIL-STD-105D
with General Inspection Level II and an AQL of 1.0%. The goal is to
determine the single sampling plan for normal inspection, including the
sample size, acceptance number, and rejection number. If 6 defects are
found in the sample, should the lot be accepted or rejected?
• Given Required
• n=?
• the lot size (N) =2,500 units
• c=?
• General Inspection Level II • r=?
• single sampling plan for normal inspection • And to decide whether the lot is
• AQL of 1.0%. to be rejected or accepted with
defect number 6

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Solution
• Using General Inspection Level II, the next step is to find the
sample size code letter from Table I in MIL-STD-105D
• For a lot size of 2,500 with inspection Level II, the code letter
assigned is K.
• The sampling plan is determined using Table II-A (Single
Sampling Plans for Normal Inspection)
• For code letter K and an AQL of 1.0%, the required sample size is
125 units
• n = 3 & r=4
• Therefore, the decision is the lot has to be rejected.

The probability of observing exactly d defectives is given by the binomial

distribution
n!
P(d)  f (d)  pd (1 p)nd
d!(n  d)!
The pa is the probability that d, the number of defectives, is less than or equal to c.
This means that
c
n!
Pa  pd  c   p d (1  p) nd
d 0 d!(n  d )!

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• Example 1
• Calculate the probability of acceptance (Pa) for a single sampling plan where
the sample size n=52, the acceptance number c=3, and the incoming lot has a
defect rate of 1% (pd=0.01). Use the binomial distribution (exact method) to
determine Pa.

Solution
c
n!
Pa  pd  c   p d (1  p) nd
d 0 d!(n  d )!
𝒏
• Pa= ∑𝒄𝒅 𝒅
𝟎 𝒅 (𝒑) (𝟏 − 𝒑)
𝒏 𝒅
𝟓𝟐
• Pa = 𝟑
(𝟎. 𝟎𝟏)𝟑 (𝟏 − 𝟎. 𝟎𝟏)𝟓𝟐 𝟑
+ 𝟓𝟐
𝟐
(𝟎. 𝟎𝟏)𝟐 (𝟏 − 𝟎. 𝟎𝟏)𝟓𝟐 𝟐
𝟓𝟐
+ (𝟎. 𝟎𝟏)𝟏 (𝟏 − 𝟎. 𝟎𝟏)𝟓𝟐 𝟏
𝟏
𝟓𝟐
+ 𝟎
(𝟎. 𝟎𝟏)𝟎 (𝟏 − 𝟎. 𝟎𝟏)𝟓𝟐 𝟎
Pa = 𝟎. 𝟗𝟗𝟖

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• Example 2
• Calculate the probability of acceptance (Pa) for a single sampling plan where
the sample size n=52, the acceptance number c=3, and the incoming lot has a
defect rate of 2% (pd=0.02). Use the binomial distribution to determine Pa.

c
n!
Pa  pd  c   p d (1  p) nd
d 0 d!(n  d )!
𝒏
• Pa= ∑𝒄𝒅 𝒅
𝟎 𝒅 (𝒑) (𝟏 − 𝒑)
𝒏 𝒅

𝟓𝟐
• Pa = 𝟑
(𝟎. 𝟎𝟐)𝟑 (𝟏 − 𝟎. 𝟎𝟐)𝟓𝟐 𝟑
+ 𝟓𝟐
𝟐
(𝟎. 𝟎𝟐)𝟐 (𝟏 − 𝟎. 𝟎𝟐)𝟓𝟐 𝟐
𝟓𝟐
+ (𝟎. 𝟎𝟐) (𝟏 − 𝟎. 𝟎𝟐)𝟓𝟐
𝟏 𝟏
𝟏
𝟓𝟐
+ 𝟎
(𝟎. 𝟎𝟐)𝟎 (𝟏 − 𝟎. 𝟎𝟐)𝟓𝟐 𝟎

Pa = 𝟎. 𝟗𝟖𝟎

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Sample table for Pa, Pd using the binomial distribution

Using this formula with n = 52 and c=3 and p = 0.01, 0.02, ...,.012 we
find

Pa 0.998 0.980 0.930 0.845 0.739 0.620 0.502 0.394 0.300 0.223 0.162 0.115

Pd 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12

Sampling Plans
c) Choosing a Sampling Plan with a given OC
Curve
How the points on this curve are obtained?
We assume that:
1.0 • The lot size N is very large, as compared
0.8 n= 52 to the sample size n, so that removing the
c=3 sample doesn't significantly change the
0.6 remainder of the lot.
Pa
0.4 • The number of defectives, d, in a random
0.2 sample of n items is approximately
binomial with parameters n and p.
0
1 3 5 7 9 11 13 15 17 19
p percent defectiveperlot

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If we are willing to assume that binomial sampling is valid, then the

sample size n, and the acceptance number c are the solution to

c
n!
1   d!(n  d )!p
d 0
d
1 (1  p1 ) n  d

c
n!
  d!(n  d)!p (1 p )
d 0
d
2 2
nd

• We can also calculate the AOQ for a (n, c) .

• Assume all lots come in with exactly a proportion of defectives.
• After screening a rejected lot, the final fraction defectives will be zero
for that lot. However, accepted lots have fraction defective p0.
• Therefore, the outgoing lots are a mixture of lots with fractions
defective p0 and 0.
• Assuming the lot size is N, we have.

p a p ( N  n)
AOQ 
N

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Example
, let N = 10000, n = 52, c = 3, and p, the quality of
incoming lots, = 0.03. Now at p = 0.03, we glean from
the OC curve table that pa = 0.930 and

AOQ = (0.930)*(0.03)*(10000-52) / 10000 = 0.02775.

Example
• A company receives inspection lots of size N=2000. They use an acceptance
sampling plan with a sample size n=200 and an incoming defect
rate p=3% (p=0.03). If the probability of accepting a lot (Pa) is 0.85, calculate
the Average Outgoing Quality (AOQ)

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p a p ( N  n)
AOQ 
N
= 0.85*0.03*(2000-200)/2000
= 0.023 (2.3%)

AOQ p
.0010 .01
.0196 .02
.0278 .03
.0338 .04
.0369 .05
.0372 .06
.0351 .07
.0315 .08
.0270 .09
.0223 .10
.0178 .11
.0138 .12

Sample plot of AOQ versus p

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A plot of the AOQ versus p is given below.

0 .0 4

0 .0 3 5

0 .0 3

0 .0 2 5
AOQ

0 .0 2

0 .0 1 5

0 .0 1

0 .0 0 5

0
0 0 .0 2 5 0 .0 5 0 .0 7 5 0 .1 0 0 .1 2 5
p = In c o m in g Q u a lity L e v e l

From examining the curve shown in figure above, we observe that:

• When the incoming quality is very good, then the outgoing quality is
also very good.
• When the incoming lot quality is very bad, most of the lots are rejected
and then inspected. Therefore, the AOQ, becomes very good.
• In between these extremes, the AOQ rises, reaches a maximum, and
then drops.
• The maximum ordinate on the AOQ curve represents the worst
possible quality. It is called the average outgoing quality limit,
(AOQL).

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Average Total Inspection (ATI)

Similarly the ATI for the above example can be calculated as follows:
• If all lots contain zero defectives, no lot will be rejected. If all items
are defective, all lots will be inspected, and the amount to be
inspected is N.
• Finally, if the lot quality is 0 < p < 1, the average amount of inspection
per lot will vary between the sample size n, and the lot size N.
• Let the quality of the lot be p and the probability of lot acceptance be
pa, then the ATI per lot is

ATI = n + (1 - pa) (N - n)

Example
A manufacturer uses a single sampling plan with a lot size N=10,000, sample
size n=52, and acceptance number c=3. The incoming defect rate is p=0.03 (3%),
and the probability of accepting the lot (Pa) from the OC curve is 0.930
ATI = 52 + (1-0.930) (10000 - 52) = 753.

(Note that while 0.930 was rounded to three decimal places, 753 was obtained using
more decimal places.)

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ATI P__
70 .01
253 .02
753 .03
1584 .04
2655 .05
3836 .06
5007 .07
6083 .08
7012 .09
7779 .10
8388 .11
8854 .12
9201 .13
9453 .14

A plot of ATI versus p, the Incoming Lot Quality (ILQ) is given in figure below

10000
Average Total Inspection (ATI)

9000

8000

7000

6000

5000

4000

3000

2000

1000

0 .0 2 0 .0 4 0 .0 6 0 .0 8 0 .1 0 .1 2 0 .1 4

p = I n c o m i n g Q u a l i ty L e v e l

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Double Sampling
• Double sampling plans: After the first sample is tested, there are three
possibilities:
• Accept the lot,
• Reject the lot, or
• No decision
• Application of double sampling requires that a first sample of size n1 is taken at
random from the (large) lot.
• The number of defectives is then counted and compared to the first sample's
acceptance number a1 and rejection number r1.
• Denote the number of defectives in sample 1 by
• d1 and in sample 2 by d2, then:
• If d1 <= a1, the lot is accepted.
• If d1 >= r1 , the lot is rejected.
• If a1 < d1 < r1, a second sample is taken.

Double Sampling

• If a second sample of size n2 is taken, the number of defectives, d2, is

counted.
• The total number of defectives is D2 = d1 + d2.
• Now this is compared to the acceptance number a2 and the rejection
number r2 of sample 2.
• In double sampling, r2 = a2 + a1 to ensure a decision on the sample.
• If D2 <= a2, the lot is accepted.
• If D2 >= r2, the lot is rejected.

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Multiple Sampling
• In this plan more than two samples are needed to reach a conclusion.
• It involves inspection of 1 to k successive samples as required to reach an ultimate
decision. Mil-Std 105D suggests k = 7 is a good number. Multiple sampling plans
are usually presented in tabular form:
• The procedure commences with taking a random sample of size n1 from a large lot
of size N and counting the number of defectives, d1.
• if d1 <= a1 the lot is accepted.

• if d1 >= r1 the lot is rejected.

• if a1 < d1 < r1, another sample is taken

Multiple Sampling

If subsequent samples are required, the first sample procedure is

repeated sample by sample. For each sample, the total number of
defectives found at any stage, say stage i, is
i
D i   d j
j1
This is compared with the acceptance number a i and the rejection
number r1 for that stage until a decision is made.

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Sequential Sampling

• This is the ultimate extension of multiple sampling where items are

selected from a lot one at a time and after inspection of each item a
decision is made to accept or reject the lot or select another unit.
• It is, however, a different from single, double or multiple sampling.
• The goal is to minimize the number of samples needed by making
decisions based on cumulative results
• Here one takes a sequence of samples from a lot. How many total
samples looked at is a function of the results of the sampling process.

Sequential Sampling
• The sequence can be one sample at a time, and then the sampling
process is usually called item-by-item sequential sampling.
• The cumulative observed number of defectives is plotted on the graph
as shown in figure.
• If the plotted point falls within the parallel lines the process continues
by drawing another sample. As soon as a point falls on or above the
upper line, the lot is rejected.
• And when a point falls on or below the lower line, the lot is accepted.
The process can theoretically last until the lot is 100% inspected.

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Sequential sampling
x r = h 2+ sn
re je c t

c o n tin u e s a m p lin g x a = - h1+ sn

Number of Defectives

h 2 accept

h1
n , n u m b e r o f ite m s

The equations for the two limit lines are functions of the parameters p1, p2,
and .
x a   h1  sn Acceptance line 
x r  h2  sn Rejection line.
1−𝛼
log
Where ℎ =
𝛽 's' typically represents the slope of the decision boundaries
𝑘

1 
log
h2  
k
 1  p1 
s  (log ) / k
1  p2 
𝑃
𝐾 = 𝐿𝑜𝑔
𝑃

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Example :
As an example, let p1 = 0.01, p2 = 0.10, = 𝛼= 0.05, 𝛽 =
.10. The resulting equations are
𝑥 = −0.978 + 0.041𝑛 𝑥 = 1.255 + 0.041𝑛

Both acceptance numbers and rejection numbers must be

integers.

Thus for n = 1, the acceptance number = -1,

which is impossible, and the rejection number = 2, which is also
impossible.
For n = 24, the acceptance number is 0 and the rejection number = 3.

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n n n n n n
inspect accept reject inspect accept reject
---------------------------------------------------------------------------------------------------
1 x x 14 x 2
2 x 2 15 x 2
3 x 2 16 x 3
4 x 2 17 x 3
5 x 2 18 x 3
6 x 2 19 x 3
7 x 2 20 x 3
8 x 2 21 x 3
9 x 2 22 x 3
10 x 2 23 x 3
11 x 2 24 0 3
12 x 2 25 0 3
13 x 2 26 0 3

So, for n = 24 the acceptance number is 0 and the rejection number is 3.

Other sequential plans are given by;

n n n
inspect accept reject
----------------------------------------------
49 1 3
58 1 4
74 2 4
83 2 5
100 3 5
109 3 6

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Skip Lot Sampling

• Skip Lot sampling means that only a fraction of the submitted lots are
inspected. This mode of sampling is of the cost-saving variety in terms
of time and effort.
• However skip-lot sampling should only be used when it has been
demonstrated that the quality of the submitted product is very good.
• A skip-lot sampling plan is implemented as follows:
• Design a single sampling plan by specifying the alpha and beta risks and
the consumer/producer's risks.
• This plan is called "the reference sampling plan".

Start with normal lot-by-lot inspection, using the reference plan.

• When a pre-specified number, i, of consecutive lots are accepted, switch to
inspecting only a fraction f of the lots. The selection of the members of that
fraction is done at random.
• When a lot is rejected return to normal inspection.
• The parameters f and i are essential to calculating the probability of
acceptance for a skip-lot sampling plan.
• In this scheme, i, called the clearance number, is a positive integer and the
sampling fraction f is such that 0 < f < 1.
• Hence, when f = 1 there is no longer skip-lot sampling.

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The calculation of the acceptance probability for the skip-lot sampling

plan is given by;
fp  (1  f ) p
i
pa ( f , i) 
f  (1  f ) p i

where P is the probability of accepting a lot

with a given p, from the OC curve .
The following relationships hold:
• for a given i, the smaller is f, the greater is Pa
• for a given f, the smaller is i, the greater is Pa

Thank you
and
?

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