Quality & AQL Inspection for Custom Plush — Verified Before Shipment

Quality Controls That Catch Issues Before Bulk Ships.

Quality is protected by staged checkpoints—materials, in-process execution, finished goods, and outgoing readiness—plus AQL-based acceptance at the release gate when required. The goal is simple: fewer defects, fewer surprises, and shipment-ready consistency backed by clear records and IP-safe proof snapshots.

What “Quality & AQL” Covers in Plush Production

Checked by stages. Released with proof.

Quality control is structured as staged checkpoints—so issues are found early, corrected fast, and verified before shipment. Coverage spans materials, production execution, final acceptance (AQL-based when required), and outgoing readiness.

Coverage includes:

Incoming material check: fabric and trim appearance, batch consistency, basic incoming condition (as applicable).
In-line checks (critical points): sewing/assembly/decoration checkpoints to prevent drift during production.
Final inspection (AQL-based): lot-based sampling for acceptance decision at the release gate (when required).
Outgoing readiness: pack-out accuracy and carton-out readiness—labels, marks, quantities, and shipment preparation checks.

What this coverage prevents (buyer-visible failures)

Bulk drift vs approved sample
Missing parts / mixed SKUs
Placement and decoration inconsistency
Carton/label errors that cause receiving delays

Quality coverage is built to stop defects early—and ship with confidence.

How AQL Inspections Run In plush production?

Inspect by triggers. Correct fast. Re-check.

Match the decoration method to artwork type, plush size, fabric texture, and end use. This section maps each option to the most stable outcome—logo readability, face expression, color coverage, and durability—so the project stays clear and consistent from sample to bulk.

1)Inputs (What Must Be Defined Before Checks Run)

Approved reference: the accepted sample standard for appearance, placement, finishing, and pack-out requirements (where applicable).
Lot setup: lot ID and batch separation rules for inspection and traceability.
Inspection focus list: product-specific “critical-to-match” points (decoration clarity, attachments, seam quality, pack-out accuracy).
Acceptance requirement: AQL-based acceptance decision at the release gate when required.

2) Execution (When Inspections Are Triggered)

Inspections run on triggers—not on memory. Common triggers include:

First-article check: first unit after setup becomes the baseline reference for the run.
Line change / operator change: checks restart at critical points after changeover.
Material change: fabric, stuffing, trims, or packaging materials change triggers verification.
Batch/lot switch: each lot is checked as its own controlled run.
Risk signals: repeated defects or visible drift triggers an immediate hold and correction loop.

3) Records (How Findings Are Logged for Verification)

Defect recording is structured by severity and type: Critical / Major / Minor (used for internal action rules).
Photo evidence is captured for recurring or high-impact defects (cropped/redacted if needed).
Batch notes link findings to lot ID, time window, and checkpoint type (incoming / in-line / final / outgoing readiness).
Release status is documented: pass / hold / rework pending.

4) Corrective Action (What Happens After a Finding)

A finding triggers an action—never “let it slide.”

Pass: continue production with the same locked reference.
Hold: isolate affected units/lot segment; stop drift from spreading.
Rework: rework only when the defect is correctable without creating new risk.
Scrap / remake: used when correction cannot guarantee consistency or safety.

5) Re-Check (How the Run Returns to Control)

Post-correction verification confirms the defect is resolved and the baseline is restored.
First-good-after-fix becomes the renewed reference for the remaining run.
Repeat findings trigger tighter checkpoints or expanded sampling within the lot until stability is proven.

Inspection runs as a control loop—so bulk stays inside the approved standard.

What Gets Checked?

Visible Failure Modes Before Shipping

Checks are organized around buyer-visible failures—the issues that show up in photos, unboxing, handling, and receiving. Each category follows the same logic: risk → checkpoints → recorded outputs.

1). Sewing & Seam Integrity (open seams, skew, thread breaks)

Risk：open seams, broken stitches, uneven panels, visible misalignment that degrades appearance and durability.

Checkpoints：high-stress seams, edge binding areas, seam intersections, symmetry/shape alignment at key landmarks.

Recorded outputs：defect type + location notes, cropped seam photos for repeat issues, rework/hold decision log.

2). Stuffing / Shape Consistency (feel, form, weight stability)

Risk：under/over stuffing, uneven firmness, leaning shapes, inconsistent weight/hand-feel across units.

Checkpoints：shape profile against reference, firmness balance across key zones (head/body/limbs), weight range consistency when specified.

Recorded outputs：shape/feel notes vs approved reference, out-of-range flags, rework actions and re-check confirmation.

3). Decoration Readability & Placement (clarity, alignment, photo impact)

Risk：blurred edges, merged lines, blocked letter openings, drifting placement, inconsistent scale across batches.

Checkpoints：logo/face clarity at normal viewing distance, thumbnail readability, placement alignment to reference landmarks (centerline/eyeline/seams).

Recorded outputs：cropped close-ups (IP-safe if needed), placement confirmation snapshots, drift flags and corrective actions.

4). Attachments & Small Parts (security, pull risk, functional integrity)

Risk：loose accessories, weak stitching points, detachment risk during handling, inconsistent attachment placement.

Checkpoints：attachment points, seam reinforcement areas, pull-risk zones (loops, straps, keychains), consistency of placement and orientation.

Recorded outputs：attachment check notes, defect photos for failure modes, isolate/rework records and post-fix re-check result.

5). Packaging Accuracy (missing parts, wrong labels, mixed SKUs)

Risk：missing inserts/accessories, incorrect barcode/label, mixed variants, carton rule mismatch that causes receiving delays.

Checkpoints：pack-out BOM match, label template match + placement rule, SKU zoning verification, carton count and packing list alignment.

Recorded outputs：pack-out verification snapshots, checklist tick records (template style), random carton-check photos (redacted if needed).

Checks focus on visible failure modes—so bulk stays brand-ready and verifiable.

How Quality Findings Feed Back Into Production ?

Find. Hold. Fix. Re-check. Lock.

Quality control only works when findings change production behavior immediately. This module shows the corrective loop that prevents the same defect from repeating across the batch—and keeps bulk output inside the approved reference.

Stop / Hold logic (containment first)

Repeated defects, visible drift, or critical failures trigger an immediate hold of affected units and batch segments.
Production continues only after the cause is identified and the baseline is restored—so defects don’t spread.

Rework criteria (fixable vs non-fixable)

Rework is used when correction can reliably return the item to the approved standard without introducing new risk.
Scrap / remake is used when correction cannot guarantee consistency, appearance, or functional integrity.

Re-check after correction (proof of recovery)

After correction, targeted re-check confirms the defect is removed and the output matches the reference again.
The first “good-after-fix” unit becomes the renewed benchmark for the remaining run.

Version locking (prevent re-introducing old mistakes)

The run is stabilized by locking the current approved reference and execution settings:
- reference sample / visual benchmarks
- process settings at critical points
- pack-out BOM and labeling version (when applicable)
Updates are treated as versioned changes—not operator decisions—so the same defect does not return in later batches.

Example Projects

Risk controlled, evidence shown.

Electronic / LED Plush (Placement + Function Check)

Project type: Electronic / LED plush with internal module + switch access requirement
Risk controlled: module position drift, switch accessibility, seam stress near wiring areas
Checks used: first-article baseline + in-line critical checkpoints + final AQL-based acceptance (when required)

Keychain Plush (High Friction + Attachment Security)

Project type: Keychain / bag charm plush with hanging loop hardware
Risk controlled: loop pull-out, edge fray, attachment placement drift, label misplacement
Checks used: attachment-point checkpoints + finished goods checks + outgoing readiness verification (pack-out/carton-out)

Mascot Plush (Large Size + Batch Shape Consistency)

Project type: Large mascot plush with strict silhouette and photo impact needs
Risk controlled: shape drift, asymmetry, decoration placement shift across batches
Checks used: first-article shape baseline + in-line profile checks + final appearance acceptance

Gift Set / Subscription Kit (Pack-Out Accuracy + Mix-Up Prevention)

Project type: Multi-item kit (plush + insert + accessory) with channel-specific packing rules
Risk controlled: missing components, wrong barcode labels, mixed variants, carton rule mismatch
Checks used: pack-out BOM verification + SKU zoning + outgoing readiness gate

FAQs about Quality AQL Inspection

Q1: What’s the difference between QA and QC?

QC is how defects are found and contained on the floor. QA is the documented system that keeps those checks consistent and auditable across batches.

Q2: Do AQL inspections apply to the whole process?

AQL is typically used for final/outgoing acceptance decisions on a lot. Earlier checkpoints (incoming and in-process) prevent drift before it reaches the release gate.

Q3: Do you support AQL inspections?

Yes. AQL sampling can be planned to match program requirements, with internal pre-checks and optional coordination for buyer or third-party inspections.

Q4: How are defects defined and judged consistently?

Defects are classified (critical/major/minor) and judged against the approved reference plus project-specific checkpoints—so decisions stay consistent across operators and lots.

Q5: How is consistency maintained across batches?

Execution and inspection criteria are tied to the approved reference, locked checkpoints, and release-gate verification—so bulk output stays inside the same standard.

Ready to partner with Uniomy and share your plush design?

Fewer defects. Clear release decisions.

Send product specs, target market/channel, and your top risk concerns to map an inspection setup: staged checkpoints, defect judgement rules, and an AQL-based release gate when required. Get verifiable outputs—inspection summaries and IP-safe photo evidence—so shipment quality is auditable, not assumed.