Although you’ll pay for the FAT, most equipment suppliers will agree to a provision that if the machine fails, any subsequent test is free. Having a detailed test plan will help ensure that you don’t short-change the FAT. Performing a brief, shallow FAT will inevitably show up as a problem in the third shift, nine months down the road. The FAT reveals weaknesses in the design and engineering phase or in the safety requirement specification phase these phases have to be modified according to the result of the FAT. In order to check the modifications the safety instrumented system has to be re- tested.
FATs are beneficial not just for the buyer and end users but for the manufacturer as well. Both parties can be assured that the equipment meets all the contractual specifications and any issues can be addressed before arriving at the customer’s site. Rectifying issues while the system is still in the possession of the manufacturer helps to keep the project on track and within budget. FATs almost always save time and money over fixing issues in the field. Our broad factory acceptance test is the most lucrative way to ensure that your equipment or plant operates correctly. As a highly qualified, independent third-party, we have the trusted skills and resources to perform steadfast testing.
What is Factory Acceptance Testing (FAT)?
The test protocol is developed during the planning and furthermore who is responsible to attest the test protocol. The procedures to carry out the FAT shall be well defined and documented in a proper way. Each test procedure shall be described in a logical sequence i.e. The needed competence for involved test personnel is described during the planning. It is recommended that personnel with experience suitable for the intended process application and safety instrumented system deals with the FAT planning.
A QA team writes acceptance tests and sets them up to examine how the software acts in a simulated production environment. Acceptance testing confirms the software’s stability and checks for flaws. Teams mature in their practice of agile use definition of factory acceptance testing acceptance tests as the main form of functional specification and the only formal expression of business requirements. Other teams use acceptance tests as a complement to specification documents containing use cases or more narrative text.
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Determine how to remove a defective part and document the process in an easy-to-use format such as a One Point Lesson (OPL). Using your technicians and operators at the FAT, practice changeovers, and start-up and shut-down protocols. See where the users encounter difficulty and elicit their input and ideas. Leverage the opportunity to modify the equipment, standardize the procedures, and document in an OPL format with numerous pictures. Many projects require a Factory Acceptance Test (FAT) prior to going on site.
Below you can find the best practices for a successful acceptance testing cycle. Acceptance tests that are unduly focused on technical implementation also run the risk of failing due to minor or cosmetic changes which in reality do not have any impact on the product’s behavior. For example, if an acceptance test references the label for a text field and that label changes, the acceptance test fails even though the actual functioning of the product is not impacted. Factory Acceptance Testing is carried out to check that the product conforms to the requirements set for it, and that it is fit for its intended purpose. If the test is passed then the product is said to be Mechanically Complete (MC) and can be passed on to the next part of the process, in which the product is installed, commissioned and put into operation. Conducted on a complete, integrated system to evaluate the system’s compliance with its specified requirements.
The procedure should include testing of as much functionality as is practical in the factory and, where possible, should show pass/fail criteria or desired results for each item tested. Once the procedure is approved, the manufacturer should test the equipment before the FAT begins. Keep in mind that some clients like to visit the factory during FAT, so this “pre-test” will confirm that the sterilizer is set up with the correct options, ensure a smoother FAT process and minimize down-time during the FAT. Acceptance testing is a test, designed and conducted to verify that specification requirements are met.
In the FAT, use the materials that will be put in operation during actual production. The FAT includes appropriate general testing procedures for verification of the correct operation of the safety instrumented system. Since the testing activities are general methods the FAT is applicable to programmable or non-programmable safety instrumented systems. The most important part of the FAT addresses specification of the test cases i.e. clear description of the test cases, well-structured test procedures and relevant test cases. Bode plots represent the actual signature (rotor response) of a rotor for a given condition of unbalance, support stiffness, and unbalance.
- A Factory Acceptance Test (FAT), is usually conducted at the manufacturer’s facility and may include functional testing and performance testing.
- This scope is communicated with the customer upfront so that all expectations and requirements can be met.
- Clearly state in the contract all the responsibilities, accountabilities, and deliverables, in a measurable way.
- To ensure that any major/critical equipment on a project meets its intended operational requirements, a factory test will typically be conducted before delivery to the site.
- Getting through the FAT is another milestone in the project, as the software has been proven in design.
- Acceptance testing can also help ensure the software or application meets compliance guidelines.
A fail suggests that there is a flaw present, and the software should not go into production. Acceptance tests verify the product actually solves the problem it was made to solve. This can best be done by the user (customer), for instance performing his/her tasks that the software assists with. If the software passes this real world test, it’s accepted to replace the previous solution. This acceptance test can sometimes only be done properly in production, especially if you have anonymous customers (e.g. a website).
Engaging the production team early in the process is one of the most important aspects of new equipment design. If training is provided as part of the FAT, make sure the people being trained are those who will run the line, not the engineers. To ensure that any major/critical equipment on a project meets its intended operational requirements, a factory test will typically be conducted before delivery to the site. The test will evaluate the equipment’s operation against its approved manufactured and operational data, which can normally be found within its technical/material submission or the equipment datasheets.
