What is a Factory Acceptance Test and Why Do You Need One?
What is a Factory Acceptance Test (FAT)?
A Factory Acceptance Test (FAT) is a series of tests performed on equipment and systems prior to installation at the customer’s site. It involves functional testing of the system, as well as testing of the system's hardware and software. These tests are done to verify that the equipment meets the specified requirements and functions as intended.
FATs are typically conducted at the manufacturer’s site but can also be conducted at the customer’s site if necessary. It aims to identify any potential problems with the equipment or system before it is installed so that these problems can be addressed before the equipment is put into service.
Purpose
The purpose of FATs is to ensure that the system meets all of the specified requirements and is ready for final installation and operational testing.
The FAT is an essential step in the process of commissioning a new factory or industrial plant. This test is used to ensure that the equipment and systems in the factory meet the required specifications and standards. It is usually performed by the manufacturer of the equipment, but it can also be done by an independent third party.
The FAT is important because it helps ensure that the equipment in the factory will work properly and safely. This test can also help identify any potential problems with the equipment or systems before they are put into operation.
Benefits
There are many benefits of factory acceptance testing, including:
The main benefits of FAT testing are that it offers peace of mind to the buyer that the equipment will meet their expectations and allows any issues to be identified and rectified before the equipment is delivered. This can save considerable amounts of time and money, as correcting problems after delivery can be much more costly and difficult.
3 Factory Acceptance Test Protocols
The test protocols for a FAT must be carefully planned and documented to ensure that all relevant aspects of the system are tested.
Below are the three test protocols to follow to have a successful test:
1. Planning
The first stage of a Factory Acceptance Test protocol is planning by establishing what needs to be tested and how it will be tested. The manufacturer, specifically the Original Equipment Manufacturer (OEM), outlines the initial scope of the FAT during the customer’s bidding phase.
The plan, which encompasses all applicable customer specifications, standards, and drawings, is written to help establish the acceptability and credibility of the equipment being supplied. By communicating the scope of the FAT to the customer at the outset, all expectations and requirements can be met.
2. Documentation
Next is documentation, wherein a set of reference documents will be compiled as reference. Some of these documents include:
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These documents are then reviewed by the manufacturer or OEM to check if the supplied equipment meets the designs required by the customer prior to the FAT.
3. Testing
This is where the testing proper happens, in which the following must be achieved:
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The 6 Stages of the Acceptance Test
There are different names, styles, and formats for acceptance tests, but in the end, the term “Final Acceptance” is meant to achieve one specific goal—a validation that the system works how, when, and where it was designed.
Below are the stages that must be taken to achieve the Final Acceptance:
How Do You Write a Factory Acceptance Test?
The FAT procedure depends on the design specifications and intended function of the machine that should undergo the testing. Even when each step of the factory acceptance testing varies per equipment, project engineers can adhere to the following standard FAT procedure:
Communicate with the client
Upon the client’s arrival at the factory floor, the manufacturer or supplier should discuss the details that have yet to be addressed before the acceptance testing. Clarifying project adjustments such as change orders shows an understanding of the client’s production process and the ability to deliver on their expectations.
Review the detailed test plan
A test plan is a tool used to clearly illustrate the timing and sequence of tests or inspections based on the equipment’s purchase order specifications and functional requirements. When walking through the test plan with the client, specify the reference documents, or the basis for the acceptance criteria, such as construction codes and verifying documents, or the proof of test or inspection results, such as certificates.
Perform safety risk assessments
Project managers should identify and eliminate hazards in the test area before commencing the acceptance testing. Complete the safety inspection with a mobile device and ensure that machinery nameplates are visible, emergency stop buttons are accessible, and safety switches are installed. Use a mobile-ready factory acceptance test checklist to verify if pre-tests were conducted, corrective actions were implemented, and all FAT personnel are equipped with the appropriate PPE.
Demonstrate equipment performance
Confirm the FAT protocol and proceed with the functional and regulatory tests—from the startup process to the maintenance procedure. As the quality team proves the performance of the custom-built machine, the client will ask questions to gauge how it will perform when installed in their facility. Ad hoc tests may be required when nonconformity is revealed.