This paper addresses issues relating to off-line inspection with rework consideration. We develop a mathematical model to determine the first unit inspected and the average number to be inspected in a batch, assuming the involvement of a quality-control department with a standard procedure. Numerical analyses are used to simulate the effect of changes in the various parameters on the optimal solution when the probability of a transition between states follows the discrete Weibull distribution. (C) 2008 Elsevier B.V. All rights reserved.