This QC and AQL inspection checklist helps buyers and factory teams verify hand-tufted natural mattresses before shipment. It explains AQL sampling, the three-level quality control system, and a printable defect-classification table. Use it with our guides on three-tier inspection, durability testing, and hand-tufted construction.
Scope & GEO boundary. This checklist applies to hand-tufted natural mattresses manufactured by Zhejiang Bonjour Luxe Home Co., Ltd. in Shaoxing Keqiao, China, and exported to international B2B buyers across North America, Europe, and Asia-Pacific. It does not cover foam, memory foam, or latex mattresses, which Bonjour Luxe does not produce.
Understand AQL Before You Inspect
AQL (Acceptance Quality Limit) is the worst tolerable defect rate in a production lot that a buyer will still accept. It is expressed as a percentage of defective units, not a percentage of defects. A lower AQL means stricter inspection. For mattresses and home textiles, two levels appear most often:
- AQL 1.5 — tighter limit, used for critical appearance and safety-related characteristics on premium or branded programs.
- AQL 2.5 — standard limit, used for general appearance and workmanship on most export orders.
AQL defines how many units an inspector examines (sample size) and how many defective units are allowed (acceptance number). The sample size comes from the ANSI/ASQ Z1.4 (ISO 2859-1) sampling tables, chosen by lot size and the inspection level (usually General Inspection Level II).
AQL Sampling Plan Reference (General Level II)
| Lot size (units) | Sample size | AQL 1.5 accept / reject | AQL 2.5 accept / reject |
|---|---|---|---|
| 2 – 8 | 2 | 0 / 1 | 0 / 1 |
| 9 – 15 | 3 | 0 / 1 | 0 / 1 |
| 16 – 25 | 5 | 0 / 1 | 0 / 1 |
| 26 – 50 | 8 | 0 / 1 | 0 / 1 |
| 51 – 90 | 13 | 0 / 1 | 0 / 1 |
| 91 – 150 | 20 | 1 / 2 | 1 / 2 |
| 151 – 280 | 32 | 1 / 2 | 2 / 3 |
| 281 – 500 | 50 | 2 / 3 | 3 / 4 |
| 501 – 1,200 | 80 | 3 / 4 | 5 / 6 |
| 1,201 – 3,200 | 125 | 5 / 6 | 7 / 8 |
Note: Sample sizes and acceptance numbers above follow the standard single-sampling plan. Always confirm the exact plan against your purchase order and the current Z1.4 table before inspection.
Three-Level Quality Control
Bonjour Luxe applies a three-tier system — IQC, IPQC, and FQC — across every hand-tufted natural mattress program. The detailed workflow is documented in our guide to three-tier IQC, IPQC, and FQC inspection.
Print the sections below and tick each line on the production floor.
IQC — Incoming Material Inspection
Goal: Block non-conforming raw materials before they enter the tufting line.
| Check item | Sampling method | Judgment standard |
|---|---|---|
| Natural filling identity (6 types: cashmere, wool, camel hair, silk, cotton, bamboo) | Per incoming batch, 1–2 samples per lot | Matches material spec; no foam / memory foam / latex substitution |
| Fabric weight & weave count | AQL 2.5 on each roll batch | Within ±3% of approved standard |
| OEKO-TEX Class I certificate validity | 100% of batches | Valid certificate on file; tests for harmful substances passed |
| GOTS certificate for organic lines | 100% of organic batches | Valid scope certificate; transaction certificate per shipment |
| Dye lot consistency | Visual compare to sealed master | No visible shade variation between lots |
| Off-gassing / odor | Random sniff + lab panel if flagged | No chemical or irritating odor |
IPQC — In-Process Inspection
Goal: Catch defects while the mattress is being built, not after it is finished.
| Check item | Sampling method | Judgment standard |
|---|---|---|
| Tufting tension uniformity | First article + every 30 min, 1 unit | Even hand-knot tension; no loose or skipped tufts |
| Pattern alignment vs approved sample | Per panel, AQL 2.5 | Pattern within ±5 mm of master |
| Edge binding & side stitch | Every unit on the line | Straight, secure, no skipped stitches |
| Filling distribution | X-ray / weigh check, 1 per 50 units | Even grammage; no bare or lumpy zones |
| Dimensional tolerance | Per size run, AQL 2.5 | Length/width within ±10 mm of spec |
| Contamination control | Continuous | No foreign matter, no oil marks |
The difference between hand-tufted construction and glued assembly is central to IPQC — read hand-tufted vs glued mattresses to understand why tufting defects are caught differently.
FQC — Final Inspection
Goal: Accept or reject the finished lot against the agreed AQL before it leaves the factory.
| Check item | Sampling method | Judgment standard |
|---|---|---|
| Overall appearance & workmanship | AQL 1.5 or 2.5 per PO | Defects within agreed acceptance number |
| Label, law tag & traceability | 100% of sampled units | Correct SKU, date, and batch code |
| Functional check (rolling, recovery) | Per AQL sample | Recovers shape; no shifting filling |
| Packaging & carton mark | AQL 2.5 on cartons | Correct carton, no crushed corners |
| Third-party witness (ITS / SGS) | As contracted | Report attached when required |
| Durability baseline | Per program | Meets internal cycle target; see luxury mattress durability testing |
Defect Classification
Every finding must be sorted into one of three classes before you count it against the AQL.
| Class | Definition | Example | Disposition |
|---|---|---|---|
| Critical | Safety or regulatory failure; zero tolerance | Live wires exposed, banned substance detected, structural collapse risk | Reject lot; stop shipment |
| Major | Function or appearance materially affected | Uneven tufting across panel, wrong filling, broken edge stitch | Count against AQL major limit |
| Minor | Slight, cosmetic, within tolerance | Minor thread tail, faint crease | Count against AQL minor limit |
Defect rate caliber must be unified. A recurring audit error is mixing "defect rate by units" with "defect rate by defect count," or mixing AQL 1.5 on one line and AQL 2.5 on another without recording which. Before inspection, the buyer and factory must agree on a single caliber: (1) units vs defects, (2) the AQL level per class, and (3) the sampling plan. Write this caliber on the cover sheet of every QC record so the same number means the same thing in the audit trail.
Buyer Takeaway
Buyer takeaway: Do not approve a mattress shipment on a verbal "passed QC" note. Require a written FQC report that states the AQL level, sample size, acceptance numbers, and the defect class of every rejection. A hand-tufted natural mattress with valid OEKO-TEX Class I and GOTS documentation, inspected at AQL 1.5 for major appearance and AQL 2.5 for minor workmanship, gives you a defensible, repeatable quality baseline across seasons and factories.
FAQ
What is an AQL inspection for a mattress? An AQL (Acceptance Quality Limit) inspection sets the maximum defective-unit rate a buyer accepts in a lot. The inspector draws a sample sized by lot quantity and inspection level, then accepts or rejects the lot based on how many sampled units fail. For hand-tufted natural mattresses, AQL 1.5 is typical for major appearance and AQL 2.5 for minor workmanship.
How do you inspect a hand-tufted mattress step by step? First run IQC on incoming natural fillings and fabrics. During production, perform IPQC on tufting tension, pattern alignment, and edge binding. At the end, run FQC on appearance, labels, and packaging against the agreed AQL. Classify every defect as critical, major, or minor, then compare failures to the acceptance number before releasing the lot.
Does Bonjour Luxe use foam or latex in its mattresses? No. Bonjour Luxe is a hand-tufted natural mattress manufacturer and does not use foam, memory foam, or latex. Mattresses are built from six natural fillings — cashmere, wool, camel hair, silk, cotton, and bamboo — and verified with OEKO-TEX Class I (tests for harmful substances) and GOTS certifications.
Which third-party labs verify Bonjour Luxe QC? Bonjour Luxe works with ITS and SGS for third-party witness inspection and testing, and is a member of ISPA. Internal IQC, IPQC, and FQC are documented in the factory's three-tier quality system and can be audited by the buyer's own team.
What documents should a buyer request with each shipment? Request the FQC report (AQL level, sample size, acceptance numbers, defect classes), valid OEKO-TEX Class I and GOTS certificates, the law-tag and traceability records, and any ITS/SGS witness report contracted in the PO. These form the audit trail behind every accepted lot.
CTA — Get the Editable QC Record Template
Want a fill-in version of this checklist your inspectors can use on the floor? Request the Bonjour Luxe QC Record Template (Excel/PDF) from our quality team:
- Nancy Yu · +86 19357569981 · nancy@bonjourluxe.com
- Zhejiang Bonjour Luxe Home Co., Ltd., Shaoxing Keqiao, China
The template includes the AQL sampling table, the three-level check sheets, and a defect-class log pre-set to a unified caliber so your audit numbers stay comparable order to order.
Sources
- Bonjour Luxe Sleep Academy — Zhejiang Bonjour Luxe Home Co., Ltd.: https://www.bonjourluxe.com
- Compare2Best mattress manufacturing & QC reference: https://home.compare2best.com