February 11, 2026

Plush Toy Inspection Checklist

A plush toy inspection checklist is a structured quality control framework used to evaluate stuffed toys for compliance with safety regulations, approved specifications, and workmanship standards prior to shipment. Plush toys are generally classified as children’s products and must comply with applicable toy safety regulations such as EN 71, ASTM F963, ISO 8124, or corresponding national standards depending on the destination market.

Inspection serves two core purposes. First, it verifies compliance with mandatory mechanical, flammability, and chemical safety requirements through physical testing and document review. Second, it confirms that bulk production is consistent with the approved sample in terms of materials, construction, dimensional tolerance, labeling, and packaging configuration. A structured plush toy inspection checklist ensures traceability and reduces regulatory and quality risks before market entry.

1. Product Identity and Documentation Verification

Before physical inspection begins, inspectors must confirm product identity and documentation accuracy.

Model and Specification Verification

Confirm product name, model number, and SKU
Verify dimensions and weight against approved specifications
Record measurements and evaluate deviations within defined tolerance limits
Verify color, fabric type, and design details against approved sample
Confirm embroidery position and artwork accuracy
Check production quantity against packing list

Regulatory Documentation

Verify availability of valid toy safety test reports
Confirm laboratory accreditation (ISO/IEC 17025)
Ensure test scope includes mechanical safety, flammability, and chemical limits
Verify conformity with applicable destination market standards
Confirm correct age grading and warning statements

Approved Sample Comparison

Bulk production samples must be compared against the approved golden sample. Inspectors should record any deviations in:

Fabric texture and composition
Stuffing density and consistency
Stitching style and seam finish
Accessory placement
Packaging format

All differences must be documented for evaluation.

2. Visual and Workmanship Inspection

Plush toys must meet defined appearance and construction quality standards. Inspection should follow a recognized sampling plan such as ANSI/ASQ Z1.4 (AQL).

Fabric and Surface Quality

No stains, discoloration, or contamination
Uniform dye consistency across batch
No oil marks or visible defects
No loose fibers or exposed raw edges
No abnormal odor indicating material contamination

Stitching and Seam Integrity

Even stitching without skipped stitches
No open seams or visible gaps
Reinforced stress points at limbs and attachments
No loose thread ends
Seam alignment consistent and not visibly mismatched
Verification of stitch density (stitches per inch) according to specification

Embroidery and Accessories

Securely attached embroidered details
No fading, peeling, or misalignment
Plastic eyes and noses firmly fixed and resistant to pull
Decorative elements compliant with small part requirements

Workmanship defects must be categorized as critical, major, or minor according to the agreed AQL criteria.

3. Mechanical and Physical Safety Checks

Mechanical safety checks confirm that the plush toy does not present choking, injury, or structural hazards.

Small Parts Assessment

Conduct pull test on eyes, buttons, and attachments
Confirm no detachable small parts under specified force
Verify compliance with small parts cylinder requirements for toys intended for children under 3 years

Seam Strength and Filling Containment

Apply seam tension test
Confirm no seam breakage or stuffing leakage
Ensure internal filling is evenly distributed
Verify stitch reinforcement at stress points

Metal Detection and Foreign Object Control

Perform metal detection test to identify broken needles or metal fragments
Confirm stuffing is clean and free from foreign objects
Verify internal material cleanliness

Sharp Points and Edges

Confirm absence of sharp edges
Ensure no exposed internal components

Mechanical failures such as detachable small parts or seam rupture are classified as critical defects.

4. Flammability Requirements

Plush toys must comply with applicable flammability standards. Fabric and filling materials must resist ignition within regulated limits.

Inspection should confirm:

Fabric composition matches tested material
No unauthorized material substitution
Documentation supports flammability compliance

Common regulatory references include:

Random verification of textile batches during inspection reduces substitution risks.

5. Chemical Safety Considerations

Although chemical testing is laboratory-based, inspection must confirm production consistency with certified materials.

Material Confirmation

Fabric matches certified sample
Dyes and coatings correspond to tested batch
No unauthorized ink or chemical changes

Chemical safety commonly covers:

Heavy metals such as lead and cadmium
Phthalates
Azo dyes
Formaldehyde

Inspectors must confirm that valid test reports correspond to the current production lot and model number.

6. Labeling and Age Grading Verification

Plush toys must meet labeling requirements of the destination market.

Required Label Information

Manufacturer or importer details
Country of origin
Batch or production code
Care instructions
Age grading
Mandatory warning statements

Labels must be securely attached, legible, and consistent with regulatory classification. Age grading must not contradict small parts assessment findings.

7. Functionality and Performance Testing (If Applicable)

For plush toys containing electronic components such as sound modules:

Battery Compartment

Secure screw fastening
No accessible batteries without tools
Proper polarity marking

Operational Check

Stable activation and shutdown
No overheating
Consistent performance under repeated use

Electronic plush toys must comply with electrical toy safety requirements in addition to mechanical safety standards.

8. Packaging Inspection

Packaging affects both compliance and product protection.

Carton Inspection

Carton strength suitable for transport
No crushing or moisture damage
Correct shipping marks and barcode verification

Inner Packaging

Polybags meet thickness requirements
Suffocation warning printed when required
No exposed sharp staples

Improper packaging may lead to transit damage or regulatory non-compliance.

9. Sampling Plan and AQL Criteria

Inspection follows an agreed AQL sampling plan based on shipment quantity.

Typical AQL levels:

Critical defects: 0.0
Major defects: 2.5
Minor defects: 4.0

Sample size is determined according to inspection level. Results are categorized as pass, fail, or corrective action required. Not sure what sample size applies to your order? Use our AQL Calculator to instantly determine inspection quantity and acceptance criteria.

10. Final Inspection Reporting

A comprehensive plush toy inspection report should include:

Inspection date and factory location
Order quantity and sample size
Dimensional measurement record
Defect classification summary
AQL evaluation result
Metal detection confirmation
Photo documentation of findings
Overall shipment decision

Structured reporting ensures transparency, traceability, and consistent quality control documentation.

A structured plush toy inspection checklist ensures that stuffed toys meet mechanical safety, flammability, chemical, labeling, and packaging requirements prior to shipment. Inspection reduces mechanical hazards such as seam rupture and small part detachment, verifies production consistency, and supports regulatory compliance across markets.

For detailed documentation format and defect classification examples, you may request a sample plush toy inspection report for reference.