How We Check Every Order — 12 Steps, AQL 2.5, Five Photo Updates
Every MedalSmith order is inspected against a 12-step standard operating procedure using AQL 2.5
sampling, and you get photo updates at five milestones: mold, sample, production, inspection and packing.
AQL 2.5 means we sample a statistically defined number of pieces from each batch and reject the lot if
defects exceed the acceptance number. Because our orders run across a network of specialist shops, this is
also the layer that makes the network usable: we own every checkpoint, and you deal with exactly one
accountable person from audit to shipment release.
The 12-step QC process
| # | Checkpoint | Reject criteria | Owner |
|---|---|---|---|
| 1 | Artwork readiness | Element thinner than 0.6mm or type under 1.5mm without written sign-off | Us |
| 2 | Die proof vs approved mock-up | Outline deviation, missing element, wrong die depth | Us |
| 3 | First strike | Short fill, visible die line, edge flash | Casting shop |
| 4 | Metal weight variance | More than ±5% from the approved sample | Casting shop |
| 5 | Edge and burr | Any burr that catches on fabric or skin | Casting shop |
| 6 | Plating tone | Visible difference from the plated reference in daylight | Plating shop |
| 7 | Plating adhesion | Lifting after tape test; bare metal in recesses | Plating shop |
| 8 | Enamel fill | Bubbles, overflow onto raised metal, color outside Pantone tolerance | Enamel shop |
| 9 | Assembly | Ribbon twist, loose clutch, capsule not seated | Assembly partner |
| 10 | Back-side engraving | Illegible characters, misaligned names, wrong sequence | Assembly partner |
| 11 | Count and packaging | Carton count short, wrong label, bag seal open | Assembly partner |
| 12 | Final pre-shipment audit | Any of the above unresolved — we do not ship on promise | Us |
What AQL 2.5 means
AQL (Acceptable Quality Limit) 2.5 is the standard most buyers and inspection companies use for
consumer goods. It defines how many pieces to pull from a batch: larger lots are sampled more heavily,
and the acceptance number scales with the sample size.
| Lot size | Pieces sampled | Accept (max defects) | Reject at |
|---|---|---|---|
| 51 – 90 | 13 | 1 | 2 |
| 91 – 150 | 20 | 1 | 2 |
| 151 – 280 | 32 | 2 | 3 |
| 281 – 500 | 50 | 3 | 4 |
| 501 – 1,200 | 80 | 5 | 6 |
| 1,201 – 3,200 | 125 | 7 | 8 |
General inspection level II, single sampling, normal inspection. Full table available
on request.
Common defects and how we judge them
| Defect | What it looks like | Our threshold |
|---|---|---|
| Bubbles in enamel | Small pits in the color surface after baking | Any bubble visible at arm's length is reworked |
| Color off-tone | Enamel reads different from the approved Pantone | Compared to the approved sample under daylight; beyond tolerance = remake |
| Burr / sharp edge | Rough rim that catches on fabric | Zero tolerance — sorted and re-tumbled |
| Plating wear | Bare metal showing after handling | Any visible base metal in a recess or on a raised edge |
| Misaligned engraving | Name or number crooked on the back | Any illegible or misaligned character is remade |
Your five progress updates
Die cut, first test strike
Plated and filled sample
Line running, count on the bench
Inspection bench and defect log
Labeled cartons before pickup
What happens if something is wrong
Defects found before shipment are reworked or remade before the carton leaves — you never see them.
If something arrives wrong, send photos within 7 days of delivery and we remake or credit the affected
pieces. The mold belongs to you, so a remake does not mean paying tooling twice.
Frequently asked questions
What does AQL 2.5 actually mean?
It is the acceptance sampling standard we inspect finished runs against: from a production lot, a statistical sample is checked, and the lot passes only if defect levels stay inside the AQL 2.5 limit. It is the same framework independent inspection companies use for consumer goods, applied to your order.
What are the five photo milestones?
Mold cut, sample, production line, QC bench and packed cartons. Each photo is timestamped, so you always know which day of the schedule you are on.
What happens if a defect is found before shipment?
We fix it before it ships — that is the point of the QC step. Defects are photographed and reported to you, and nothing leaves without our approval. If something still arrives wrong, send photos within 7 days and we remake or credit the affected pieces.