Factory Acceptance Test (FAT) Template

A Factory Acceptance Test (FAT) Template, along with a comprehensive Factory Acceptance Test Protocol, is a document used to prove that equipment or systems meet all required specs through tests done at the manufacturer’s facility. This ensures everything works, meets industry and contract specs and customer expectations before installation.

Why a FAT Template?

The FAT template is a testing blueprint, for manufacturers and customers to ensure quality, performance and reliability. Agreed upon specifications are key in this process as it ensures new equipment meets these criteria before it’s deployed. It provides a standard way to plan, execute and document tests, to avoid misunderstandings and transparency. By following a structured FAT, both parties can find issues early, avoid rework and a smooth transition from production to real world operation. FAT testing is crucial to ensure that all equipment meets functionality and performance requirements before delivery.

FAT Template Components

A well-done FAT template covers all aspects of factory acceptance tests (FATs). Here’s what it has:

1. General

This section has project information:

• Project Overview: Brief description of the project, including objectives and scope.
• Equipment: Details about the equipment being tested, including model numbers and configurations.
• Stakeholders: Contact details of key people involved, like manufacturer reps, client reps and third-party inspectors.
• Test Location & Date: When and where the FAT will take place.

2. Objectives and Scope

• Objectives: What the FAT is trying to achieve, for example confirming functionality, compliance or performance.
• Scope: What’s included in the testing process and what’s not to avoid confusion.

3. References

• Design Specs: Technical documents that define expected performance and features.
• Industry Standards & Regulations: Safety and compliance standards the equipment must meet.
• Previous Test Reports: Past quality checks relevant to this FAT.
• FAT Standards: Guidelines for quality, safety and compliance.

4. Test Methods

• Pre-Test: Before you start testing, you need to calibrate and do safety checks on the instruments. Make sure all equipment is working and the testing area is safe.
• Step-by-Step: Follow a detailed guide for the testing process to ensure consistency and accuracy. This includes instructions for each step of the testing procedure.
• Tools & Equipment: List all the instruments and materials required for testing. Make sure you have all the tools you need.
• Safety: Identify the risks involved in the testing process and outline how to mitigate them. This includes wearing personal protective equipment (PPE) and following safety protocols.
• Factory Acceptance Test (FAT) Protocol: The FAT protocol is a document that outlines the testing procedures and acceptance criteria. This is to evaluate the functionality and performance of the equipment before accepting it for use.
• Testing Procedures: Testing procedures provides clear criteria and methodologies to ensure all aspects of the equipment or system is thoroughly tested. This will help you identify any issue or defect before you put the equipment into operation.

5. Acceptance

• Performance Metrics: What equipment must meet to pass.
• Functional Requirements: What equipment should do without errors.
• Compliance Standards: System meets all regulatory requirements.
• Tolerances: Acceptable deviation limits.
• Functional Testing: Part of the FAT checklist.

6. Results and Documentation

• Data Sheet: Templates to record results, observations and measurements.
• Pass/Fail Criteria: Clear definition of what constitutes pass or fail.
• Anomaly Report: Defects and unexpected behavior.
• Photos: Images or videos to support test findings.

7. Non-Conformance Issues

• Deficiency Reporting: How to report issues found.
• Root Cause Analysis: Process to investigate defects.
• Corrective Action Plan: Steps to fix problems.
• Re-Test: How equipment will be re-tested after corrections.

8. Approvals

• Test Conductors Signatures: Tests were conducted correctly.
• Witness Signatures: Client or third-party approvals.
• Final Sign-Off: Equipment is approved for shipment.

9. Additional Documents (Appendices)

• Glossary: Definitions of technical terms in the FAT.
• Test Data Sheets: Blank forms to record test results.
• Calibration Certificates: All testing instruments were calibrated.
• Equipment Drawings: Schematics for reference.

Factory Acceptance Test (FAT) Templates

Factory Acceptance Testing (FAT) is a critical step to ensure equipment, machinery or systems meet contractual specifications, industry standards and customer requirements before they are shipped and installed at the final site. FAT helps to identify issues early, reduce costly delays and modifications during commissioning. It’s especially important to verify quality and compliance of industrial equipment before it reaches the customer. In contrast, Site Acceptance Tests (SAT) are conducted at the client’s location after installation to ensure the equipment functions correctly in its intended environment and integrates with existing systems.

Here are some useful FAT templates to standardize and streamline the testing process:

1. Vention FAT Checklist

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• Provides a structured checklist for verifying machine performance, safety, and compliance.
• Allows customization based on specific project requirements.
• Helps document test results efficiently to ensure all acceptance criteria are met.

2. Sitemate FAT Checklist

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• Covers key aspects such as visual inspections, functional tests, and safety evaluations.
• Designed to improve documentation and traceability of FAT processes.
• Can be adapted to different industries, including manufacturing, automation, and construction.

3. Lumiform FAT Template

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• Offers a digital checklist for conducting FAT with real-time documentation.
• Helps teams identify defects, assign corrective actions, and track progress.
• Supports mobile access, making it easier for on-site teams to conduct and report tests.

4. GoAudits FAT Checklist

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• Provides a comprehensive checklist for verifying compliance with technical and safety requirements.
• Includes sections for equipment identification, inspection criteria, and test results.
• Useful for both suppliers and customers to ensure mutual agreement on performance expectations.

Regulatory Compliance and Industry Standards

A FAT template is structured to comply with multiple industry regulations and standards. Depending on the industry, the following standards may apply:

• ISO 9001: Quality management systems
• IEC 61508: Functional safety of electrical/electronic systems
• ASME B31.3: Process piping compliance
• API 610: Centrifugal pump standards for petroleum, petrochemical and natural gas industries

Following these guidelines ensures the equipment meets the safety, operational and environmental regulations before it leaves the factory.

Common Challenges

While the FAT process is important, it can be challenging:

• Inadequate or Vague Test Plans.
  • Solution: Make sure the FAT template has a full test procedure with clear acceptance criteria.
• Lack of Communication Between Teams.
  • Solution: Define roles and responsibilities for all stakeholders and have pre-FAT meetings.
• Unexpected Non-Conformities.
  • Solution: Have a robust non-conformance tracking system and a corrective action plan. And SAT (Site Acceptance Test) is crucial to verify the equipment works as intended in its environment after installation.
• Time Constraints.
  • Solution: Plan FAT well in advance, allow enough time for testing, troubleshooting and approvals.

How to Customize a Factory Acceptance Test Template

Every organization and industry is different. Customizing the template ensures it’s project specific. Here’s how:

• Modify Testing Criteria: Change the performance parameters to match customer requirements.
• Add Extra Safety Checks: Add industry specific safety and compliance checks.
• Use Digital Data Logging: Integrate automated systems to capture and analyze test results.
• Add Client Specific Approval Sections: Tailor the approval and sign off process for each customer.

Conclusion

A Factory Acceptance Test (FAT) template is a vital tool to ensure equipment reliability, compliance and performance before delivery. By following a standard FAT format, manufacturers and customers can reduce risks, improve product quality and project execution. Having a defined FAT process saves time, reduces costs and customer satisfaction.