Fundamentals of AQL Testing in Packaging Control - Online Training Recording

Course No. 21425



Torsten Kneuss

Torsten Kneuss



In this online course, you will learn the fundamentals of AQL Testing in Packaging/Device Control. AQL testing as part of the incoming good inspection process is commonly used. But still, questions often arise. It is this webinar’s aim to aid here and to explain statistical fundamentals behind the AQL testing concept, like, for example:
  • Definition of AQL – what does it mean in regard to the accepted lot? What is the level of possible defects?
  • How to use defect evaluation lists?
  • How are quality levels determined and how is the number of units to be inspected calculated?
  • What does AQL testing look like for supplier and user?
  • What has to be done when AQL limits are exceeded?


Usually, the responsibility of ensuring the container/device quality upon delivery to users (e.g. pharmaceutical companies) rests with the manufacturers (suppliers) of packaging materials. However, users are held responsible by regulatory requirements to ensure suitability of containers/devices for their products. Therefore, users should conduct sampling of incoming packaging/ device lots to confirm their acceptability according to predetermined quality agreements.
Expecting defect-free containers from a supplier does not eliminate the need for some degree of incoming and online inspection, as well as post-packaging inspection. However, acceptance sampling of incoming batches by users has its limitations. Care should be taken to understand the “risks” of the sampling plan and the defined defect class / Acceptable Quality Levels (AQLs). Every AQL testing contains the statistical possibility of accepting a lot that is “bad” or rejecting a lot that is “good” (consumer’s and producer’s risk).
Since it is not practical to inspect incoming lots to 100% and to expect container lots to be free of imperfections, it is important that users and suppliers consistently define sample sizes, attributes and AQLs. Defect evaluation lists containing sample sizes, defect classes (Critical, Major or Minor), attributes and AQLs can provide such consistency.

Target Group

This online event is designed for all employees working in the pharmaceutical industry (including drug device combination products), for suppliers of packaging materials & devices and to all who have to deal with the manufacture, quality assurance/ control and release of packaging materials /devices.

Technical Requirements

To participate in an on demand training course or webinar, you do not need any software. The recordings are made available via a streaming server. In general, the recording is provided in MP4 format, which any PC (Microsoft Windows, Apple IOS) or tablet can easily Display.
Timing and Duration:
When you register for the on demand Training course or webinar you can decide at what date you want to follow the training course online. For a 1-day training course you will have 2 days in which the stream is available (for 2-day training course 3 days and for a 3-day training course 4 days). Within in this timeframe you can start & stop the stream according to your needs.
In time before the scheduled date (your desired date) you will receive an e-mail from us with a link for direct participation as well as your log-in data.

Please be aware: The recording does not include the Q & A sessions.
Training Course Documentation and Certificate:
The presentations will be made available as PDF files via download shortly before the online training course.  After the event, you will automatically receive your certificate of participation.


Practical Challenges & Definitions
  • Definition of lot size/batch size
  • Distribution of defects
  • Attributes testing vs. variable testing
Introduction to Statistics
  • Probability calculus
  • Define the confidence level (95%; 99%)
  • Standard Statistical Distributions (Normal, Binomial)
Sampling Plans
  • Methods to determine sample sizes (ISO 2859, ISO 3951)
  • Single, Double, Multiple Sampling Plans
Acceptable Quality Level (AQL)
  • Definition of AQL
  • Producer Risk/Consumer Risk
  • Operating Characteristic
Defect Evaluation Lists
  • General methods for Defect Evaluation/AQL assignment
  • Public Defect Evaluation Lists
Acceptance Sampling by Attributes (ISO 2859)
  • Use of ISO 2859
Acceptance Sampling by Variables (ISO 3951)
  • Use of ISO 3951
Other statistical tools
  • Significance testing
  • Setting specifications (defining LSL/USL)
  • Process capability (Cpk)
Recording from 23 November 2023
Duration of the recording: 3h 53min

ECA-Member*: € 1090,-
Regular Fee*: € 1190,-
EU/GMP Inspectorates*: € 595,-
APIC Member Discount*: € 1140,-

(All prices excl. VAT). Important notes on sales tax.

* also payable by credit card
American Express Visa Mastercard

Further dates on-site
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Further dates online
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Please contact us:
Tel.: +49 6221 8444-0

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