Sampling plans exist precisely because testing everything is expensive, and they define the statistical relationship between sample size and lot-wide inference.
If the entire lot failed qualification, a retest on a different vial is sometimes done, but reporting a retest result under the same lot number is misleading.
To be exact about it, published segregation failures show that even modern automated processes sometimes produce lots with measurable vial-to-vial variation.
Sampling plans for pharmaceutical manufacturing are defined in ISO 2859 and ANSI Z1.4, and they are based on statistical sampling theory.
One qualification: testing more vials gives better confidence, but at some point the cost outweighs the benefit.
Assume segregation is possible, and design your sampling to catch it if it exists.
edited 8 Mar 2026 by eoin_mcgarry — tightened the wording; no substantive change