When equipment issues appear after installation, the average cost of fixing them can range from 10-25% of the total project budget. A proper factory acceptance test (FAT) can significantly reduce these costs since you’ll be able to spot issues early, before installation even happens.
From complex machinery in manufacturing to critical software systems, a FAT verifies that the delivered product performs as promised. It’s an essential part of the quality assurance process. In this guide, you’ll find out how factory acceptance testing works and why it matters, along with tips for conducting it effectively.
What is a factory acceptance test (FAT)?
A factory acceptance test is used to verify that newly manufactured equipment functions in accordance with the order specifications and design rules. A factory acceptance test can be used in plant construction and mechanical engineering as well as in the software sector or information technology.
This procedure, also known as factory acceptance test, is performed in the production plant by quality managers, designers, operating, and maintenance personnel prior to delivery and installation at the customer’s site.
Purpose of a factory acceptance test
The FAT as a critical checkpoint in the project timeline, allowing you to catch potential issues early in a controlled environment:
- Quality assurance: It ensures the equipment is built and performs according to predefined standards.
- Cost savings: Identifying and fixing issues during the FAT stage is far more economical than addressing them on-site.
- Improved communication: The FAT encourages collaboration between manufacturers and clients so both parties agree on expectations and results.
- Operational readiness: It reduces the chances of sudden problems during the installation phase.
What’s the difference between a factory acceptance test and a site acceptance test?
A factory acceptance (FAT) happens before the equipment leaves the manufacturer’s facility. It focuses on checking if the equipment meets the design specifications, quality standards, and customer requirements in a controlled environment.
On the other hand, a site acceptance test (SAT) takes place at the equipment’s final destination, usually after installation. The goal of the SAT is to confirm that the equipment works as intended in its actual operating environment, given real-world conditions.
While FAT is about the “what” (does the equipment meet specifications?), SAT is about the “where” (does it work properly where it will be used?). Together, they provide a comprehensive quality assurance process.
What are the steps in a factory acceptance test?
1. Checking the delivery
During a factory acceptance test checklist, the delivery is checked for completeness and the contractually stipulated provisions. After the test, the information is documented in a protocol: the factory acceptance test template.
2. Functionality
After the first check, the goods are subjected to a functional test. This involves a conventional functional test and a simulation test.
3. Checking the documentation
All components are checked for completeness and quality stipulated in the contractually agreed upon documents. This includes manuals, instructions, and assembly plans.
4. Dispatch preparation
After the functionality test, the packaging is examined for any defects or damages. Only when the first points have been successfully completed for the customer, the plant or system is released for delivery.
To streamline the process, you can choose from Lumiform’s factory acceptance checklists, which guide you through each of the steps above.
What are the 4 common factory acceptance test problems?
Overlooked deviations in the equipment can lead to installation problems on-site, which can upset the project schedule. Prior to delivery, quality managers should resolve the non-conformity at the factory to ensure that the customer’s new processing lines are ready for operation on time.
Here are 4 common problems discovered during factory acceptance testing and what countermeasures quality teams can take to ensure equipment reliability.
1. Poor machine quality or craftsmanship
There should be regular coordination between quality managers, designers, and production managers to ensure that the technical drawings (electrical, mechanical, pneumatic, and process diagrams) are followed to their specifications. Before factory acceptance, calibration certificates should be prepared for the instruments.
In addition, managers should consult datasheets on the instruments and materials in order to deliver high-quality products with performance customers can rely on.
2. Non-compliance with legal or sanitary requirements
Customers often specify production standards for their ordered devices. Boilers, pressure vessels, and bioprocess plants can obtain international certifications through conformity assessments, which makes them even more trustworthy. For electrical and electronic products, systems, and services, most manufacturers follow the International Electrotechnical Commission (IEC) standards.
To ensure that design specifications are met, quality managers may also consider working with industrial hygienists or health and safety officers.
3. Lack of suitable machine shielding and labeling
Before and after coordination with customers, FAT checks should be carried out on the machine safety devices. Quality managers are responsible for overseeing operators and maintenance personnel with installation, maintenance, user manuals, recommended spare parts lists, and easy-to-use training material. Lock-Out Tag-Out (LOTO) markings and procedures should also be clearly defined to meet health and safety standards.
4. Lower throughput than expected
Quality managers should provide customers with all records of the agreed factory acceptance test and a step-by-step protocol for review and approval. During the actual test, the machine’s functionality should be verified by a series of validation tests based on a consensus acceptance criterion and a list of defects (compilation of non-conformities for modification).
Best practices for conducting factory acceptance tests
These strategies will help you maintain clarity and efficiency throughout the test and reduce the chances of the mistakes listed above:
- Develop a detailed test plan. This document acts as a guide, outlining every step of the process, from the specific procedures to the criteria for acceptance. Aside from procedural details, the test plan should also describe the roles of everyone involved, from technicians to client representatives.
- Prepare thoroughly. All necessary equipment, tools, and documentation should be ready before the test begins, such as specialized testing devices and safety gear. For documentation, include design specifications, operational manuals, and compliance standards that you might need to reference during the test.
- Use a checklist. A checklist is an invaluable tool to stay organized and focused, reducing the risk of human error. It ensures that team members can methodically complete every step of the process, from test preparation to final documentation, without oversight.
- Document everything. Meticulously record every test result, whether a pass or fail, with details like measurements, observations, and deviations from expectations. Include supporting evidence too such as photos or data logs, along with a record of decisions and discussions that occur during the test.
- Address issues promptly. The moment you detect a discrepancy or failure, classify it by severity so you can tackle the most critical issues first. Once corrective actions are implemented, retesting should follow immediately to confirm the fix’s success.
How does an app help to prove the reliability of the equipment?
With a digital solution, your company can reliably complete factory acceptance tests. You can easily carry out recurring inspections via tablet or smartphone. Using the desktop software, you can create checklists for your daily factory acceptance tests and then evaluate the collected data.
FAT records are easier to complete with orderly documentation, ensuring equipment reliability from pre-delivery through to customer installation. With Lumiform, companies benefit from:
- The checklist builder helps you to convert any individual paper list into a digital checklist without effort.
- Using the super intuitive mobile app, you and your teammates can conduct checks in the field seamlessly.
- All results, images, and comments are automatically bundled in a digital report.
Try it now with a 14-day free trial and conduct faster, more accurate factory acceptance tests!