When you’re purchasing new factory equipment, it’s important to ensure that it is properly tested before it’s delivered to your site. This is what a factory acceptance test (FAT) is for—to ensure that the equipment meets all of your expectations and functions as expected.
This article will discuss what a FAT is and how to make a factory acceptance test checklist. We’ll also go over some tips on successfully completing a FAT.
What is a Factory Acceptance Test?
A factory acceptance test (FAT) is a process that verifies if newly purchased factory equipment meets the requirements before it’s delivered to the customer’s site. A FAT is usually performed by quality managers, operators, design engineers, and maintenance personnel in the manufacturing facility before the equipment is delivered and installed at the client’s site.
Why is Factory Acceptance Test Important?
A factory acceptance test is important because it ensures that the equipment functions properly and meets all expectations. This test can also help prevent costly downtime and production delays once the equipment is installed since any issues will have been identified and resolved before delivery.
Benefits of Factory Acceptance Test
Performing FAT provides many benefits to both the supplier and the client. Some of these benefits include:
- Verify tie-in connection points: By verifying tie-in connection points, you can ensure that the factory equipment will interface correctly with the existing site equipment.
- Review safety systems: FAT reviews the safety systems to ensure that they function properly and meet all safety requirements.
- Ensure compliance with standards: A FAT can help ensure compliance with standards such as ISO, CE, etc.
- Reduced downtime and production delays: As mentioned earlier, having a FAT can help prevent costly downtime and production delays once the equipment is installed at the customer’s site.
- Ensure equipment meets performance specifications: A FAT is a great way to ensure that the equipment meets all performance specifications.
- Test communication protocols: Testing communication protocols ensure that the factory equipment can communicate properly with the existing site equipment.
- Identify and correct errors before delivery: Avoid costly delays and rework by identifying and correcting errors before delivery.
- Improve communication: The FAT process can help improve communication between the supplier and the client.
How to Write a Factory Acceptance Test Protocol
Right before shipping, a factory acceptance test is done at the vendor’s equipment manufacturing site. A good FAT helps mitigate problems that occur during the delivery and installation of the equipment. When writing a FAT protocol, make sure you follow the steps below:
- Step 1 – Purpose: Write the purpose of the FAT protocol to establish the objectives of the test. The purpose statement should ensure that the equipment is designed according to the specification and to check if the performance of the equipment is up to par with product standards.
- Step 2 – Scope: The scope sets the parameters of what will be included in the FAT. This will help ensure that all necessary tests are conducted and that nothing is missed. The scope statement should go like “this factory acceptance test protocol applies to the equipment manufactured by Vendor Ltd.”
- Step 3 – Procedure: This section of the FAT protocol should outline the steps that need to be taken in order to test the equipment. The procedure is written in a step-by-step format to be easily followed. The procedure should also include the following:
- The actual procedure to check equipment operation.
- Actions to be taken when deviations are observed
- List of relevant documents to be checked.
- Step 4 – Documentation: Make sure you document everything done during the FAT process. This includes everything from the test setup to the actual results of the tests. All documentation should be kept in a central location so that it can be easily accessed by everyone involved in the project.
- Step 5 – Acceptance Criteria: Equipment and accessories should be in accordance with the purchase order. On the other hand, equipment should be according to the pre-designed parameters.
- Step 6 – Verification Sheet: Include all tests and parameters on items that need verification during the factory acceptance test. These include:
- Make: mention the make of the equipment.
- Model: mention the actual model of the equipment.
- Capacity: mention the capacity requirement of the equipment.
- Design: the design should contain the following details:
- Parts of the equipment and their specification and design.
- MOC (material of construction) of all parts as SS-308 or SS-316.
- Quantity and other details of the specific equipment parts.
- Control Panel: Write quantity and requirement that are included in the control panel (e.g., auto or manual, emergency stop)
- PLC: mention the PLC panel’s make, model, and quantity.
- Temperature sensors: mention the make, type, quantity, and model of the temperature sensors.
- RH Sensors: mention the model, make, and quantity of the RH sensors.
- Safety Features: mention the type of emergency stop, electric parts, guards on moving, etc.
- Documents: create a list of required documents such as manuals, calibration, warranty cards, certifications, and MOC certification.
- Step 7 – Monitor Deviations: Mention the deviation that you observed during verification, investigation, and corrective action—determine whether or not these points are acceptable.
- Step 8 – Conclusion: At the end of the FAT protocol, write a conclusion statement that summarizes your findings. This should mention whether or not the equipment has passed or failed. It should include whether or not the equipment meets the requirements and if it is ready to be shipped or not. If any issues need to be addressed, mention them as well.
- Step 9 – Approval: Create an approval section where you include the names and signatures of the people who have reviewed and approved the factory acceptance test protocol. This ensures that everyone involved in the project has signed off on the testing that has been concluded.
Create a FAT Checklist with DataMyte!
If you want your factory acceptance test protocol to be more effective and efficient, you’ll need to utilize a FAT checklist to keep track of everything that needs to be done. The DataMyte Digital Clipboard lets you create a FAT checklist template that you can use for your next project!
With the DataMyte Digital Clipboard, you’re able to:
- Create comprehensive FAT checklists that cover all aspects of factory acceptance testing
- Edit and customize your FAT checklist template to fit the specific needs of your project
- Share your FAT checklist with other members of your team so that everyone is on the same page
- Track progress and ensure that all factory acceptance tests are being completed in a timely manner
- Get real-time reports and analytics on your factory acceptance tests so that you can identify areas for improvement
If you’re looking for a better way to manage factory acceptance testing, look no further than the DataMyte Digital Clipboard! Our user-friendly platform will streamline the factory acceptance testing process and help you avoid costly mistakes.
Contact us today to learn more about how we can help you streamline your factory acceptance testing process!
To ensure the equipment you bring to your facility is up to snuff, you need to put it through a factory acceptance test (FAT). Use the information in this guide to help you understand what a factory acceptance test is, why you need to do one, and how to create an effective factory acceptance test checklist. And if you want to make your factory acceptance testing process more efficient, consider using the DataMyte Digital Clipboard.