AQL

INSPECTION &
WAREHOUSE
GUIDELINE
REFERENCE TO A0029 AQL INSPECTION POLICY
REFERENCE TO A0386 AQL INSPECTION PROCEDURE
FOOTWEAR QUALITY
CONTENT
1. ROOM SET-UP
2. DOCUMENT PREPARATION
3. SAMPLING AND INSPECTION PREPARATION
4. INSPECTION PROCESS
5. FINALIZING INSPECTION
6. MCS HANDLING
7. STICKERS AND STAMPS STANDARDIZATION
8. OUTER CARTON SEALING
9. VISUAL COLOR MANAGEMENT
10. CATRON STORAGE

11. WAREHOUSE PROCESS FLOW

12. EXAMPLE FOR WAREHOUSE LAYOUT
AQL INSPECTION & WAREHOUSE GUIDELINE

ROOM SET-UP
AQL INSPECTION ROOM SET-UP (1 OF 2)

As described in A0029 AQL Inspection Policy (FTW), the following points are to be adhered to when establishing, updating,
and/or maintaining and inspection room:
• The inspection room is to be used by authorized personnel for inspection-related purposes (e.g., not used as a meal room,
no general storage of goods, no general meetings, training related to inspections is OK, etc.)
• Only the staff necessary to perform inspections should be presented
• The inspection room must be sized to handle the inspection of at least 300 pairs from 30 cartons
• The room must be painted white, air conditioned and well-lighted (either natural or appropriate artificial light)
• Light intensity range is to be 650-800 lux as measured at 5 positions on final inspection table (see images next
page)
• A large white surfaced table is required. A minimum of 2 meters by 1meter
• On top of the table a 100% flat marble stone plate (50cm/50cm) should be placed to check if the shoes are rocking
(If the table covered whole surface by glass then flat marble stone is no longer required)
• Securable glass door storage for MCS (Manufacturing Confirmation Sample)
• A complete and updated QIP manual must be available when needed (NOTE: this may be kept on a computer, tablet, or
other electronic device)
• SHAS manual must be available for any POs requiring special handling (NOTE: this may be kept on a computer, tablet, or
other electronic device)
• Table I (sample - size Code letters) and Table II (Master table for normal inspection) must be posted on the wall
AQL INSPECTION ROOM SET-UP (2 OF 2)

190-
220 cm

100cm
200cm

The light intensity has to be 650-800 LUX If the table was covered whole
1 4 measured with a LUX Meter at the center surface by glass then flat marble
and all four corners of the inspection table stone is no longer required
3 (as shown at the image above)
Light height: 190-220 cm
Marble Table length: 200 cm
2 5
Table width: 100 cm
AQL INSPECTION TOOL KIT

 Red Arrow Stickers

 QIP Checked Stickers (for sealing cartons)
 B-grade stamps (red and silver/grey)
 Non-metal Cutter
 Pen/Pencil
 Board Marker (to update status boards)
 Ruler – 6” steel
 Measuring tape for laces
 Stitch length gauge
 Pinchers (use for checking bottom bonding,
edges must be rounded)
 Shore A Hardness Gauge (rubber)
 Asker C Hardness Gauge (phylon/EVA)

• Digital weight scales may

be required for selected
NOTE: Computerized AQL products
reports must guarantee
personal and secure signatures. (NOTE: The max. tolerance is
+/- 1g)
 AQL INSPECTION & WAREHOUSE GUIDELINE

DOCUMENT PREPARATION
AQL INSPECTION PREPARATION

• Prior AQL Inspection following documents have to be ready and available:

o Inspection Certificate
o Grading Sheet to check e.g. size grouping of lace length and logo dimensions
o SHAS & Packing Manual to check packing integrity

• AQL calculation has to be done by Quality administrative staff prior the inspection and provided to AQL
inspector

• Computerized Inspection Certificate and all necessary documents have to guarantee personal and secure
signatures.

NOTE: The factory has to ensure prior to shipment of a PO that all shipping documents according to the shipping
instructions (SI) are available.

FOOTER / PRESENTATION NAME 20-FEB-19 8

SAMPLING PLAN
Identify Inspection Level for T1:
For AQL use General Inspection LEVEL II
For BA use General Inspection LEVEL I
Identify Inspection Level for LOP & LOQ:
For AQL validation use General Inspection S-4
Split of large POs into smaller Inspection Lot sizes
-> the maximum allowed inspection Lot size is 3.200 pairs
A) PO size = 10.000 pairs
• Split PO according to maximum Inspection Lot
size of 3.200 pairs
 A PO of 10.000 can be split into 3x 3.200 + 1x 400
pairs for inspection
B) PO size = 25.000 pairs
• Split PO according to maximum Inspection Lot
size of 3.200 pairs
 A PO of 25.000 can be split into 7x 3.200 pairs +
1x 2.600 pairs for inspection
Note: To above scenarios A) & B) are just examples to
illustrate how PO’s greater than 3.200 pairs can be split.
ACCEPTABLE QUALITY LEVEL REMAIN AT 2.5
AQL INSPECTION QUANTITY PER SIZE - SAMPLING CALCULATION

Calculation Method to get the Inspection Quantity for each Size:

Use ANSI AQL Insp. Calculation Form (Table III): Calculation Table
Enter order quantity for eachsize.
Enter ‘total Inspection Quantity”

Method ANSI / AQL Calculation Table III

MODEL Inspection Level /

P/O No CUST.NAME CUST.ORD ART ETD 6 6- 7 7- 8 8- 9 9- 10 10- 11 11- 12 12- 13 13- QTY
NAME Multiplication %

60 90 90 90 110 140 170 170 130 90 90 70 80 20 1400 Level2 / K

To-be inspected sample qty per size 5.4 8.0 8.0 8.0 9.8 12.5 15.2 15.2 11.6 8.0 8.0 6.3 7.1 1.8 125 8.9%

Selected Qty 5 8 8 8 10 13 15 15 12 8 8 6 7 2 125

Results
Inspection quantity per size.
Sample lot % automatically generated – to be entered into InspectionReport.
 AQL INSPECTION & WAREHOUSE GUIDELINE

SAMPLING AND INSPECTION

PREPARATION
AQL SAMPLING - CARTON SELECTION

Select Cartons andBoxes

• AQL Inspector will randomly select cartons according to what
has been calculated in the AQL Calculation Table III.
• Pick additional carton if quantity exceeds 10 / 20 / 30 / etc pairs.
• Randomly select boxes from carton according to determined inspection quantity per
size.

Fill in Inspection Report (except defect listing) – carton selection (computerize system)
AQLINSPECTION - SELECTING OUTER CARTONS INWAREHOUSE

HSV
13 d=35mm

QIP

• Cartons per size are randomly selected from Packing List and pulled from
warehouse.
• AQL Inspector is stamping each carton selected and pulled from the Warehouse
with his/her inspection stamp (white base with black letters)
• The stamp shall be placed below the PO Label as shown in above picture
AQL INSPECTION PROCESS PREPARATION

Cut tape +/- 6” from center Cut both ends Cut tape from one end

35 mm
Line QC CHECKED

95 mm

through center Pull flaps open by hand.

Do not rip off the sealing
tape while opening the
carton!

• Cartons are brought into AQL Inspection Room, aligned on floor in order by size
• AQL Inspector has to check if all cartons which have been selected in FG WH are in inspection room
• AQL Inspector has to check if the Line QC checked sticker is placed on top and bottom side over the yellow tape
• Cartons are only opened by inspection assistant after the AQL Inspector asks for opening
AQL INSPECTION PROCESS PREPARATION

Check the packing

• Outer cartons and inner boxes match with packing list and
SHAS

• Model is correctly identified on outer/inner carton. Cartons

and inner boxes in good condition

• Outer and inner box bar code labels are readable, not covered,
torn or stained

• Labels and contents match

• Outer/inner box labels are straight and in their proper

position
AQL INSPECTION PROCESS PREPARATION

• AQL Room Assistant unpacks shoes and removes paper stuffing from all pairs to be
inspected
• Used tissue paper is put aside and can be re-used for packing if it is not torn or damaged
• In case the tissue paper is damaged a new paper must be used for packing
AQL INSPECTION PROCESS PREPARATION

• Shoes are placed on top of the inner box for inspection

FOOTER / PRESENTATION NAME 20-FEB-19 18

AQL INSPECTION MANUFACTURING CONFIRMATION SAMPLE

• AQL Inspector checks MCS sample date to ensure it has been reviewed within the past 90
days
• MCS has to be without any wrappings in order to compare MCS with shoes to be inspected
FOOTER / PRESENTATION NAME 20-FEB-19 19
AQL INSPECTION EVALUATION STANDARDS

• Inspect each pair of shoes for the defects listed in the Link to defect list
• There is not a classification of defects (i.e., critical, major, minor) in footwear at this point
• However, due to the impact of bonding gaps in the market, the inspection for bonding gaps is held to a higher
standard where bonding gaps are not allowed to be more than 40% of Rejection Number for the sample size
inspected, e.g.:


o
o

• A shipment is accepted or rejected according to inspection results

NOTE: The factory has to ensure prior to shipment of a PO that all shipping documents according to the shipping
instructions (SI) are available.

FOOTER / PRESENTATION NAME 20-FEB-19 20

 AQL INSPECTION & WAREHOUSE GUIDELINE

INSPECTION PROCESS
COMPARE MCS WITH PRODUCTION SHOE

• MCS must be compared with same sample size from PO to be inspected

• In case the sample size is not available in the PO, then use next closest size to compare

FOOTER / PRESENTATION NAME 20-FEB-19 22

COMPARE MCS WITH PRODUCTION SHOE

• Compare shoes with MCS to ensure correct materials, colors, design, bottom,
components, sockliners, free lace length and shape of shoe

NOTE: MCS must be available throughout the entire inspection process

MEASURING TOTAL LACE LENGTH

• Laces on the 1st pair of sample size every size group must be removed (done by inspection
assistant) and measured
• Length must be in accordance with spec / grading sheet
• Logo sizes should be checked randomly with spec / grading sheet

FOOTER / PRESENTATION NAME 20-FEB-19 24

PACKING INTEGRITY

• Check size labels to ensure that they are the same on both left and right shoes,
the inner box, and hang tag.
• Check that article, production month and PO number are readable.
CHECKING INSIDE OF THE SHOES

• Feel for wrinkled linings or • Check that sockliners have the

collar padding correct length
• Feel for misplaced heel counter • Check if the sockliner are in correct
that may cause irritation for the position
consumer
CHECKING OF THE TONGUE

• Ensure that tongue is centered and secure. Grab tongue top between thumb and
forefinger and pull firmly.
• Check tongue position and length, check tongue logo, emboss, embroidery or printing.
CHECKING OF THE VAMP

• Check shoes outside if toe cap, vamp, eye stay, tongue and heel are centered and
in line
• Check the stitching lines, the eye stay alignment and if eyelets are proper fixed
• Look for cosmetic defects such as dirt, stains or excess cement
• Check inside the shoes for cosmetic defects such as dirt, stains, sockliner mis-
placement, excess cement, wrinkles or loose lining
CHECKING OF THE HEEL

• Check for crooked heels, logos, embossing, embroidery, printing or

poor stitching quality.
• Check that mid- and outsole heights are at the same level (left – right)
• Check that back tabs are centered
CHECKING OF LATERAL AND MEDIALSIDE

• Check for excessive wrinkles, damaged upper, accurate side lasting, shoes matching as a
• pair, stripe alignment, overall stitching quality.
• Check over-roughing and over-cement or cements spots.
CHECKING OF BOTTOM UNIT

• Check for correct length, clean and clear logo execution

• Check for color bleeding, damaged rubber or EVA
• Check for dirt or excessive cement
CHECKING OF STABILITY AND TOESPRING

• With shoes standing on a flat marble stone, place fingers on heel tops (medial collar & lateral
collar) to check stability. A little wobbling of the shoe can be accepted (based on training and
experience)
• Toe spring height should be matching MCS and being the same in pairs
CHECKING OF BONDING QUALITY

• Press down firmly with the thumb to check bonding of upper to midsole or upper to
outsole.
• Randomly pincers are used to check bonding between outsole and midsole (can be
done on flat outsole edge only).
• Link to the video
DEFECT IDENTIFICATION / MARKING
Bonding Gap
• Red Arrow Stickers are
applied to identify defects
found during the inspection
RELEASED
• Pairs without defects found
are handed to inspection
assistant with toes together
on top of inner box to identify
them as released
REJECTED
• Pairs with defects are handed
to inspection assistant with
shoes reversed (toe to heel) on
top of inner box to identify
them as rejected
HANDLING OF BEAUTIFUL AUDIT IN AQL INSPECTION ROOM

Additionally to the current adidas AQL inspection policies and standards, all POs are
audited according to Beautiful Product Criteria.

• The Beautiful Audit shall be done on completed POs using the General Sampling Plan
minimum require at Level I (refer to sampling plan at slide 9)

• In the Beautiful Audit the selected shoes must be inspected and evaluated against the
8 Beautiful audit criteria - enter link to the criteria

• A shoe or pair of shoes can fail in more than 1 criteria; all failures need to be recorded
in the respective report - enter link to the report

• Beautiful Audit results ARE NOT used to pass, reject or lock a PO

• Beautiful Audit results will be collected and used to measure and monitor the progress
on raising the quality awareness to achieve our desired goal to create ‘The Most
Beautiful Sports Product’
 AQL INSPECTION & WAREHOUSE GUIDELINE

FINALIZING INSPECTION
HANDLING OF RELEASED AND REJECTED SHOES AFTER INSPECTION
• Rejected shoes are placed on a rack or
shelf until inspection is completed
• The rack shall be used to enable the
AQL inspector, but also the adidas
production manager to easier identify
and review the rejected shoes.
• Replacement shoes must be checked
by AQL Inspector prior adding them to a
PO.
• Released pairs are re-wrapped with
tissue paper ( Used tissue paper can be
re-used for packing if it is not torn or
damaged, In case the tissue paper is
damaged a new tissue paper must be
used for packing )
MARKING OF B-GRADE PRODUCTS

Stamping process for adidas and Reebok:

• Stamp “B” on lateral lining under heel collar foam

• use silver/grey pen for B-grade on black or dark lining
• use red B grade stamp on white or light colored lining
MARKING OF AQLINSPECTEDPAIRS

HSV
13 d=12mm

QIP

• AQL inspector identification stickers (white base with black letters) are placed on the lower left hand corner
on the inside of the box lid for released pairs.

• On inner boxes with separate lids, the stickers are placed in the lower left hand corner directly above
ventilation hole.
SEALING OF AQLINSPECTED OUTERCARTONS

• Cartons are resealed with grey sealing tape placed over the original yellow sealing tape on top of the
carton.
• The AQL Inspector places a green “QIP Checked” sticker directly over the top of the original sealing sticker
from production on the top of the carton.
• The AQL Inspector then stamps with the personal QIP Inspector stamp (white base with black letters) so
that the stamp is positioned half on the QIP Checked sticker and half on the carton.
SEALING OF 100% RE-INSPECTED OUTERCARTONS

• In case a PO has to be 100% re-inspected by production after a failed AQL inspection,

a “100% Inspected” sticker must be used to identify all outer cartons
 AQL INSPECTION & WAREHOUSE GUIDELINE

MANUFACTURING
CONFIRMATION SAMPLE –
MCS HANDLING
HANDLING OF THE MANUFACTURING CONFIRMATION SAMPLE - MCS

•
•
•

•
•
HANDLING OF THE MANUFACTURING CONFIRMATION SAMPLE - MCS

• a hole with the size of 10mm has to be punched in the medial heel area, hole should
not be in areas with specific design, material and/or grain features.
• if any signatures from Development and/or production are on the MCS they must sign
on the medial heel or midsole area.
HANDLING OF THE MANUFACTURING CONFIRMATION SAMPLE - MCS

Storage of MCS
a) MCS must be stored in re-sealable polybags so that the shoes can be easily taken out
b) Poly bags with MCS must be stored in inner boxes to protect the samples from sunlight
(max. 2 MCS in one inner box)
c) All inner boxes with MCS must be stored in cabinets which can be locked
HANDLING OF THE MANUFACTURING CONFIRMATION SAMPLE - MCS

The inner box must be labeled at least with:

• Model Name of MCS MCS Inner Box Label
• Article number of MCS
• MCS checking card must attached on the lid with the date the MCS was last checked and signed off
MCS Checking Card
HANDLING OF THE MANUFACTURING CONFIRMATION SAMPLE - MCS

Review Process (Re-signing Process)

When NO issues were found during reinspection of the MCS, then the AQL Inspector:
• has to fill out and sign the MCS hangtag
• add the MCS re-signed hangtag to the backside of the original hangtag MCS Re-sign Tag
• update MCS Review Tracking Report
HANDLING OF THE MANUFACTURING CONFIRMATION SAMPLE - MCS

Exchange process (Re-make process)

In case a replacement of the MCS is needed:
• the AQL Inspector must inform the QIP Manager that the
MCS must be replaced
• the replacement MCS must match the original MCS
• Punch a hole with size 10mm diameter in the medial heel
area
• MCS „Re-make“ samples have to be signed with date by

• add the MCS Re-make hangtag to the backside of the

original hangtag MCS Re-make Tag
• update MCS Review Tracking Report
 AQL INSPECTION & WAREHOUSE GUIDELINE

STICKERS AND STAMPS

STANDARDIZATION
AQL STAMP AND STICKERS STANDARDIZATION

• QIP sticker for inner R

box to identify final
random inspected
shoes

• sticker for inner box to

identify 100%
inspection after failed
AQL (also to be used
for partial reinspection)

• TQC sticker for inner

box after lines tollgate
QC inspected.

FOOTER / PRESENTATION NAME 20-FEB-19 50

AQL STAMP AND STICKERS STANDARDIZATION

• Line QC Checked
sticker to seal outer
cartons after TQC
inspection on line.

• QIP Checked sticker to

seal outer cartons
after AQL inspection by
certified AQL inspector

FOOTER / PRESENTATION NAME 20-FEB-19 51

AQL STAMP AND STICKERS STANDARDIZATION

• QIP stamp to identify

outer cartons in FG WH
HSV
after AQL inspection 13 d=35mm

QIP

Stamping the outer Carton is a signature process!

The personalized Inspector stamp must be placed half on the sticker and half on the
outer carton after sealing.

FOOTER / PRESENTATION NAME 20-FEB-19 52

AQL STAMP AND STICKERS STANDARDIZATION

• 3rd party sticker in

inner box to identify
shoes inspected.

• 3rd party sticker to seal

outer cartons after
inspection.

• 3rd party stamp to seal

outer cartons after
inspection

Above pictures show examples for 3rd party stamp and sticker. In different countries
minor variations in design are possible. Please refer the detail in A0373 3rd party
inspection procedure FOOTER / PRESENTATION NAME 20-FEB-19 53
 AQL INSPECTION & WAREHOUSE GUIDELINE

OUTER CARTON SEALING

PROCESS
OUTER CARTON SEALING
After TQC inspection at end of line
• Seal with yellow tape
• Line QC CHECKED: place “Line QC
CHECKED” sticker over the tape
(both sides of outer carton)
Re-inspect for some cartons as issue on the lines
• Resealing with yellow tape, place
over the original tape
• Place “Line QC CHECKED” sticker
over the tape, covering original
sticker
FOOTER / PRESENTATION NAME 20-FEB-19 55
OUTER CARTON SEALING

After AQL Repacking after AQL After AQL re-inspection

(100% re-inspection)

• Reseal with grey tape • Reseal with yellow tape • reseal with grey tape
over the original tape. over original tape • QIP CHECKED: place
• QIP CHECKED: place • 100% Inspected: place “QIP CHECKED ”
“QIP CHECKED ” sticker “100% Inspected ” sticker over “100%
directly over the top of sticker directly over the Inspected ” sticker
the original sealing top of the original • QIP Stamp
sticker sealing sticker
• QIP Stamp FOOTER / PRESENTATION NAME 20-FEB-19 56
OUTER CARTON SEALING

After TQC inspection but with re-

packing required

• Seal top of outer carton with a thin
clear tape
• Bottom of outer carton sealed with
yellow tape
• Line QC CHECKED: place “Line QC
CHECKED” sticker over the tape
(both sides of outer carton)
• All open carton edges have
to be sealed to close the OC
properly, same as per
standard sealing operation.
FOOTER / PRESENTATION NAME 20-FEB-19 57
OUTER CARTON SEALING

After 3rd party inspection

• Resealing with grey tape, place over the original tape

• place 3rd party sticker over the tape, covering original sticker
• Please refer the detail in A0373 3rd party inspection procedure

FOOTER / PRESENTATION NAME 20-FEB-19 58

AQL INSPECTION & WAREHOUSE GUIDELINE

VISUAL COLOR
MANAGEMENT
VISUAL COLOR MANAGEMENT

20-Feb-19 60
VISUAL COLOR MANAGEMENT
VISUAL COLOR MANAGEMENT
VISUAL COLOR MANAGEMENT
VISUAL COLOR MANAGEMENT

20-Feb-19 64
VISUAL COLOR MANAGEMENT

E) PO storage in F/G warehouse for Pull Forward / MTF Orders

Pull forward /MTF orders have to be stored in FG WH or a lockable separate warehouse

section, all outer cartons must be sealed (refer to 2. Outer Carton Sealing Process).
White playcards are used to identify the status with following basic information:

PO/Pull forward/MTF#

Art name

Quantity

Production month

Note:
Maximum storage time is 3 months.
After 3 months storage a 100% inspection is mandatory to re-evaluate quality of shoes (e.g.
yellowing, aging or fungus).

20-Feb-19 65
 AQL INSPECTION & WAREHOUSE GUIDELINE

CARTON STORAGE
CARTON STORAGE

20-Feb-19 67
 CARTON STORAGE

• •
 AQL INSPECTION & WAREHOUSE GUIDELINE

WAREHOUSE PROCESS
FLOW
WAREHOUSE PROCESS FLOW

F/G IN

Scan to SIS
system

Stacking

Send to
inspect
Inspection
NG

OK

Wait for
shipment
 AQL INSPECTION & WAREHOUSE GUIDELINE

EXAMPLE FOR WAREHOUSE

LAYOUT
EXAMPLE FOR WAREHOUSE LAYOUT