The FAT Test Validates the Machine Solution And Gives Peace of Mind – Know This As a Customer
May 14, 2024
Factory Acceptance Test, commonly known as FAT, is a key test phase in the process of ordering an industrial automation solution and a special purpose machine before handing it over to the customer. It is not an exaggeration to say that a reliable, professional machine manufacturer can be identified specifically through carefully performed FAT testing.
Basically FAT, the factory acceptance test, is performed by the manufacturer in its own premises before the delivery of the machine solution to the customer’s premises.
However, it is most optimal to carry out the test so that the customer’s representative is also there to monitor the testing event with the project team that prepared the solution. The observations made together create the most solid basis for agreeing on the acceptance of the test or drawing up a plan for further measures based on the observed shortcomings.
The ABC of FAT testing
Primarily, the FAT test ensures that the finished machine fulfills the specifications and other contractual requirements recorded in the order contract.
In practice, the test serves as a concrete quality control report before the machine is put into production. In this blog post, we open up in more detail:
- Why is FAT crucially important from both the customer’s and the machine manufacturer’s point of view?
- Which areas does the test cover?
- Why is FAT important at Metecno?
FAT test provides important information
The meaning of FAT is more multifaceted than just ensuring that everything works as planned.
In general, a successful FAT eliminates unnecessary material costs, loss of working time and trouble brought by extra work, when the machine solution does not reveal unpleasant surprises during the commissioning phase.
- Quality assurance: FAT ensures that the customer receives a machine that meets his expectations and order. It reduces surprises that require repair during installation.
- Shorter commissioning time: When the device has been tested and approved in the FAT test, its commissioning time at the customer’s premises is shortened significantly. This saves time and resources.
- Minimising risks: Early identification of anomalies reduces costly changes or delays during implementation.
- No production stoppage: By solving problems before delivery, FAT prevents production downtime due to machine malfunction.
- Peace of mind: Both the customer and the manufacturer gain confidence that the ordering process for the machine solution has been successful and that it meets the requirements set for the solution by both parties.
Almost as a rule of thumb, it can be considered the idea that it is significantly cheaper to correct deficiencies and errors identified before implementation than after implementation.
“Just as you shouldn’t compromise on the design, manufacturing or safety of the machine, you shouldn’t skimp on testing it either.”
Areas to be verified with FAT
Planning is the starting point of FAT testing. The areas to be tested and their test methods must be carefully considered before starting the actual testing.
When, for example, the following questions are answered during the test, the acceptance test can already be considered quite reliable:
- Mechanical integrity: Are all the components installed correctly, are there any strange noises coming from the machine or does the machine work mechanically smoothly?
- Electrical systems: Do the cabling, sensors and control system work as planned, or do questionable solutions for future use already appear at this stage?
- Safety features: Do the emergency stop buttons, locks and safety mechanisms work as they should? Is the device sure to comply with safety standards?
- Software and automation: Is the software working properly? Have communication protocols been created?
- Performance metrics: Does the machine meet production quality, accuracy and product lead time requirements?
It is important to note, however, that a successful FAT test does not completely exclude malfunctions arising from use. FAT says that the machine is ready for production work at that very moment.
On the other hand, the warranty granted by the manufacturer plays a bigger role in solving defects caused by use, since the machine has literally been driven hard in continuous production.
At Metecno, the FAT test is relevant
Despite our highly lean design and manufacturing processes, we do not take the factory acceptance test lightly. On the contrary, the FAT test performed by us with piety is an integrated part of the ISO-certified overall delivery of our special purpose machines.
We keep in close contact with the customer during the project, so that mutual understanding of the implementation of the solution in relation to the initial data is maintained. It is quite common for questions to arise during the design process that require changes to the drawings. We make the desired changes to the pictures and after the customer approves the design, we start the assembly process.
The effort to build a special purpose machine from scratch for demanding production use arouses thoughts in both the manufacturer and the customer. Although the expertise of the makers, the manufacturing technologies and methods used are of a high standard, the result of combining all the variables cannot be fully predicted. This is where a well-prepared and implemented FAT test shows its power.
The illustration image shows only the test frame built for the FAT test of one special purpose machine. The frame, whose dimensions (L x W x H) are 8.5 m x 4.5 m x 4.5 m, is quite a lot of work to design and build for just one test. Especially when directly after the test we disassemble the frame; of course, we strive to reuse the components as efficiently as possible.
Our attitude towards the FAT test is strong and our investment in this specific FAT test can be considered significant, because we also bear the cost responsibility for the implementation of the test framework. However, Metecno’s priority as a company is to ensure that the planned special purpose machine works flawlessly before it is delivered to the customer.
Our message to companies considering machine investment is: ask already at the ordering stage how the service provider plans to implement the FAT test? Based on that alone, you can help evaluate the company’s way and ability to execute the entire order.
For more details
If our blog has raised further questions or you need advice on how to run a successful FAT test, please contact us and one of our experts will be happy to answer your questions: info@metecno.fi