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Factory Acceptance Test

Facilitate a factory acceptance for your company and your customers by using digital checklists for each acceptance test procedure.

Go paperless, conduct inspections easily and solve issues quicker with your teammates.

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Factory Acceptance Test Checklist

Use this checklist for the Factory Acceptance Test (FAT) to document the complete/incomplete FAT protocol.

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Site Acceptance Test Checklist

This Site Acceptance Test (SAT) checklist is used for the process of validating the reliability of newly manufactured equipment with other interfaces at the site.

Download template

Weekly Manufacturing Quality Control

This weekly checklist for quality control in manufacturing helps you to maintain the specified quality standards.

Download template

What is a factory acceptance test?


A factory acceptance test is used to verify that newly manufactured equipment functions in accordance with the order specifications and design rules. 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.



This article deals with the following topics:


1. Why is a checklist used for a factory acceptance test?


2. Progress of a factory acceptance test


3. Effective countermeasures to the 4 common FAT problems


4. A digital solution to streamline the FAT



Why is a checklist used for a factory acceptance test?


If a checklist is used for factory acceptance, costly project delays can be avoided. This is done by ensuring the completion of the FAT protocol, such as standard operating procedures, welding process qualifications and certificates of conformity, and the implementation of the correct test procedure for the Factory Acceptance Test.



progress of a factory acceptance test


    1. Checking the delivery

    First of all, the delivery is checked for completeness and the contractually stipulated provisions during factory acceptance. After the factory acceptance test, the information is documented in a protocol: the factory acceptance test template.


    2. Functionality

    After the first checks, the goods are subjected to a functional test. This involves a conventional functional test and a simulation test.


    3. Check of the documentation

    For all components the completeness and quality of the contractually agreed documents is checked. This includes manuals, instructions and assembly plans.


    4. Dispatch preparation

    After the functionality test the packaging is tested. Only when the first points have been successfully completed for the customer, the plant or system is released for delivery.



    4 common factory acceptance test problems and effective countermeasures


    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 in their actual state. Before factory acceptance, calibration certificates for the instruments should be prepared and the data sheets of the instruments and materials should be consulted in order to deliver high-quality instruments with a performance that customers can rely on.


    2. Non-compliance with legal or sanitary requirements


    Customers often specify standards for the production of their ordered devices. Boilers, pressure vessels and bioprocess plants can obtain international certifications through conformity assessments, which make them even more trustworthy. For electrical and electronic products, systems and services, most manufacturers follow the standards of the International Electrotechnical Commission (IEC). 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 labelling


    Before and after coordination with customers, FAT checks should be carried out on the machine safety devices. Quality managers are responsible for providing operators and maintenance personnel, installation, maintenance and 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 protocol step by step for review and approval. During the actual factory acceptance test, the functionality of the machines 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).



    How does Lumiform help to prove the reliability of the equipment?


    With Lumiform, the powerful inspection application, factory acceptance tests can be performed in any company. FAT protocols are easier to complete with proper documentation, ensuring equipment reliability from pre-delivery to installation at the customer's site. With Lumiform, companies benefit from the following advantages:


    Individual digital forms

    The flexible form construction kit makes it possible to create new individual checklists at any time and to adapt them again and again.


    First class customer service

    Lumiform’s excellent 24/5 support will reliably answer all your questions about the app when you need assistance using the tool.


    Scheduling and notifications

    The Lumiform App ensures that the schedule is kept. All employees receive notifications about the procedure and due dates. Managers automatically receive notifications when assignments are overdue and problems have occurred.


    Time-defined work steps

    Keep an eye on your schedule and use the information to identify opportunities to increase your efficiency.


    Faster identification and resolution of problems

    The data you collect from inspections is collected under the Analysis Tab. Here you can access all data and view your performance reports broken down by time, location and department. This helps you quickly identify causes and problems so you can fix them as quickly as possible.


    Track inspections in facilities over time

    Monitor your team’s inspection performance and identify opportunities to improve the process and efficiency of your operations.


    Integrations

    Connect Lumiform’s Software to enterprise software systems.


    Time-defined targets

    Keep an eye on what’s happening and identify insights from the information gained to increase your efficiency.



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