Factory Acceptance Testing (FAT): Complete Guide for Manufacturers

Meta Description: Learn how to conduct effective Factory Acceptance Testing. Discover procedures, checklists, and best practices for equipment and system verification.

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Introduction

Factory Acceptance Testing (FAT) is the process of verifying that equipment or systems meet specified requirements before shipment to the customer's site. Proper FAT prevents problems during installation and commissioning.

What Is Factory Acceptance Testing?

FAT is a series of tests conducted at the vendor's facility to verify that the equipment or system meets all requirements and specifications.

┌─────────────────────────────────────────────────────────────────┐
│              FAT in the Project Lifecycle                       │
├─────────────────────────────────────────────────────────────────┤
│                                                                 │
│  REQUIREMENTS → DESIGN → BUILD → FAT → SHIP → SAT → OPERATION   │
│                           │                                     │
│                           ▼                                     │
│                   Verify at Vendor                              │
│                   Before Shipping                               │
│                   Easier to Fix                                 │
│                                                                 │
│  FAT: Factory Acceptance Test (at vendor)                       │
│  SAT: Site Acceptance Test (at customer site)                   │
│                                                                 │
└─────────────────────────────────────────────────────────────────┘

Why FAT Is Important

Benefits of Proper FAT

FAT Process

Phase 1: Preparation

┌─────────────────────────────────────────────────────────────────┐
│              FAT Preparation Checklist                           │
├─────────────────────────────────────────────────────────────────┤
│                                                                 │
│  REQUIREMENTS                                                  │
│  ☐ Specifications defined                                      │
│  ☐ Acceptance criteria established                             │
│  ☐ Test procedures documented                                  │
│  ☐ Success criteria clear                                      │
│                                                                 │
│  LOGISTICS                                                     │
│  ☐ FAT scheduled                                               │
│  ☐ Attendees identified (customer, vendor, integrator)          │
│  ☐ Travel arrangements                                         │
│  ☐ Duration planned (typically 1-5 days)                       │
│                                                                 │
│  DOCUMENTATION                                                 │
│  ☐ Test procedures prepared                                    │
│  ☐ Checklists created                                          │
│  ☐ Forms for results recording                                 │
│  ☐ Issue tracking prepared                                     │
│                                                                 │
│  EQUIPMENT                                                     │
│  ☐ Test equipment available                                    │
│  ☐ Measurement tools calibrated                                │
│  ☐ Required materials available                                 │
│  ☐ Safety equipment provided                                   │
│                                                                 │
└─────────────────────────────────────────────────────────────────┘

Phase 2: FAT Execution

FAT TEST SEQUENCE:
1. Visual Inspection
2. Documentation Review
3. Static Tests
4. Dynamic Tests
5. Operational Tests
6. Integration Tests
7. Performance Verification
8. Safety Testing
9. Cleanup/Restore
10. Results Review and Sign-off

Phase 3: Documentation

FAT DOCUMENTATION DELIVERABLES:
☐ FAT plan (pre-approved)
☐ Test procedures
☐ Test results
☐ Issues list (open and closed)
☐ As-built documentation
☐ Calibration certificates
☐ Software/firmware versions
☐ FAT report with sign-off

FAT Test Categories

1. Visual Inspection

INSPECTION CHECKLIST:
☐ Equipment matches specifications
☐ Construction quality acceptable
☐ Proper materials used
☐ No visible damage
☐ Adequate access for maintenance
☐ Safety guards installed
☐ Labels and nameplates present
☐ Paint and finish acceptable
☐ Proper grounding
☐ Conduit and wiring neat and secure

2. Documentation Review

DOCUMENTATION CHECKLIST:
☐ Manuals provided (operation, maintenance)
☐ Drawings (electrical, mechanical, layout)
☐ Bill of materials
☐ Spare parts list
☐ Software documentation
☐ Certifications (CE, UL, etc.)
☐ Calibration certificates
☐ Test reports
☐ Data sheets
☐ Safety documentation

3. Functional Testing

FUNCTIONAL TESTS:
☐ Individual component operation
☐ Sequence verification
☐ Interlock testing
☐ Alarm and indication testing
☐ Control system functionality
☐ HMI/SCADA interface testing
☐ Communication testing
☐ Power supply verification
☐ I/O verification

4. Performance Testing

PERFORMANCE VERIFICATION:
☐ Capacity verification
☐ Speed verification
☐ Accuracy verification
☐ Repeatability testing
☐ Throughput verification
☐ Quality verification
☐ Efficiency verification
☐ Environmental condition testing

5. Safety Testing

SAFETY VERIFICATION:
☐ Emergency stop testing
☐ Safety circuit testing
☐ Guard switch verification
☐ Light curtain testing
☐ Pressure relief verification
☐ Temperature protection testing
☐ Lockout/tagout points verified
☐ Warning labels verification
☐ Safety distance verification

FAT Common Findings

Typical Issues Discovered

FAT vs. SAT

FAT Checklist Template

Mechanical Equipment

EQUIPMENT: _______________________ DATE: ________
VENDOR: ________________________ FAT #: ________

VISUAL INSPECTION
☐ Dimensions per drawing
☐ Materials of construction correct
☐ Welds acceptable
☐ Fasteners correct and tight
☐ Alignment acceptable
☐ Bearings/lubrication correct
☐ Guards installed properly
☐ Nameplates installed

FUNCTIONAL TESTS
☐ Manual operation successful
☐ Automatic operation successful
☐ Sequence correct
☐ Interlocks function
☐ Emergency stop works
☐ Alarms function correctly

PERFORMANCE VERIFICATION
☐ Speed meets specification
☐ Capacity meets specification
☐ Accuracy meets specification
☐ Repeatability acceptable

DOCUMENTATION
☐ Manual provided
☐ Drawings provided
☐ Spare parts list provided
☐ Calibration certs provided

ISSUES:
_______________________________________________________________
_______________________________________________________________

OVERALL RESULT: ☐ PASS ☐ PASS WITH MINOR ☐ FAIL

SIGNATURES:
Vendor: _________________ Date: ________
Customer: _______________ Date: ________

Best Practices

For Successful FAT

1. Plan Thoroughly

   • Detailed test procedures
   • Clear acceptance criteria
   • All stakeholders aligned

2. Attend in Person

   • See equipment operate
   • Meet vendor team
   • Training opportunity

3. Test Realistically

   • Simulate actual conditions
   • Test with real materials if possible
   • Verify all functions

4. Document Everything

   • Record all results
   • Photograph equipment
   • Note all issues

5. Follow Up Issues

   • Ensure all problems resolved
   • Re-test as needed
   • Document resolution

Common FAT Mistakes

FAT for Different Equipment

Control Systems

CONTROL SYSTEM FAT:
☐ I/O testing (all points)
☐ HMI/SCADA testing
☐ Alarm verification
☐ Trend/logging verification
☐ Recipe testing
☐ Security testing
☐ Network communication
☐ Backup/restore testing
☐ Redundancy testing

Mechanical Equipment

MECHANICAL EQUIPMENT FAT:
☐ Dimensional verification
☐ Alignment checks
☐ Run-in testing
☐ Load testing
☐ Vibration testing
☐ Temperature verification
☐ Noise level verification

Software Systems

SOFTWARE FAT:
☐ Installation testing
☐ Functionality testing
☐ Integration testing
☐ Performance testing
☐ Security testing
☐ User acceptance testing
☐ Data migration testing

Conclusion

Factory Acceptance Testing is a critical quality gate that prevents problems later when corrections are more expensive. Thorough preparation, clear acceptance criteria, and complete testing ensure successful FAT results.

Need help planning your FAT? Contact us for FAT procedure development and support.

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Related Topics: Site Acceptance Testing, Commissioning, Equipment Qualification