Classify defects by business risk
Updating a Quality Plan When a Supplier Changes is best approached as a measurable packaging decision, not a visual preference. Critical defects can create safety or regulatory risk; major defects can prevent sale or proper use; minor defects affect appearance without defeating the pack. Define examples for glass, decoration, pump, cap, assembly and carton before inspection. Photographs and boundary samples reduce interpretation differences.
Combine process checks and final sampling
A final AQL inspection is not a substitute for stable production. Use first-piece approval, in-process checks and final lot sampling together. Record mould position or cavity where relevant, because recurring defects may be concentrated in one production source.
Test performance, not only appearance
Include leakage, spray dose, priming, cap retention, assembly and transit performance according to the pack's risks. Use filled samples and defined orientations, temperatures and durations. Agree acceptance criteria before testing so a result is not reinterpreted after a failure.