Factory Acceptance Testing vs Site Acceptance Testing

Once your test specifications have been defined, the equipment can be set up and configured for testing. Some cost-impact items to consider include the cost of procuring the equipment, labor and material costs relative to any control, power or communications wiring, and the labor and area to stage the equipment. Keep in mind that while small setups may be very inexpensive, as systems increase in size, so does the impact of planning, space, labor, and costs. When writing code for automated systems, it is necessary to demonstrate that the code is written to the customer’s specifications. At Matrix Technologies, Inc., we begin our projects by listening to the customer’s needs and writing a functional document describing how we will address those needs.

definition of factory acceptance testing

Any instrumentation used to record data during the test will be verified to be within the calibration date as required by manufacturer or customer specifications, prior to the test. A Factory Acceptance Test is used to verify that newly produced equipment works according to its construction code and purchase order specifications. It is performed by quality managers, design engineers, operators, and maintenance personnel in the manufacturing facility before delivery and installation at the clients’ site. Most of the time testers not only check that the equipment meets the specification, but also that it is fully functional. A FAT usually includes a check of completeness, a verification against contractual requirements, a proof of functionality and a final inspection. The objective is to provide confidence that the developed product meets both the functional and non-functional requirements.

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Testing can cover a variety of inspection points based on specific requirements and unique equipment specifications. Typical FAT areas at the fabrication center include electrical power, clean steam, hot and cold water, clean air, and other utilities for testing skid systems, clean-in-place systems, and custom fabrications. FATs are beneficial not just for the buyer and end users but for the manufacturer as well.

  • Test scenarios usually differ from System or Functional test cases in that they represent a “player” or “user” journey.
  • Factory Acceptance Testmeans those tests conducted to determine that equipment or other Materials comply with the applicable specifications and contractual requirements prior to shipment to the Shipyard.
  • Factory Acceptance Testhas the meaning set forth in the applicable Purchase Order.
  • Some of the applicable industrial standards such as API 598 and ISO 5208 are briefly reviewed in this chapter.
  • The SFAT will include all reference documents, drawings, and process and instrument diagrams and follow a predetermined test procedure defining the acceptance criteria, detailed instructions, and expected results.

While there are similarities between the two, they are distinct processes. The following blog post outlines the key differences between FAT and SAT. P&ID / GAD walk-down – verify all lines and components are present and installed as per P&ID/GAD. Check that components are new, anchored sufficiently to frame, and are built in accordance with the specifications outlined in the applicable list.

Vessel Nameplate Review:

The SFAT will include all reference documents, drawings, and process and instrument diagrams and follow a predetermined test procedure defining the acceptance criteria, detailed instructions, and expected results. The procedure is generated by the system integrator and approved by the engineer before the FAT. Given the value of factory acceptance testing, choosing a manufacturer who offers FAT is an important first step in the design/build process. User acceptance testing consists of a process of verifying that a solution works for the user. It is not system testing but rather ensures that the solution will work for the user (i.e. tests that the user accepts the solution); software vendors often refer to this as “Beta testing”. The initial scope of the FAT to be supplied by the manufacturer / OEM is done during the bid phase of the customer’s order.

Testing performed at the factory has several advantages, especially the advantage of identifying problems before the equipment leaves the factory. There is no “extra cost” for the customer to have an FAT performed on their system as it is generally included in the scope of the project. That being said, the expense that is factored into the project for FAT is dependent on the customer’s requirements. It is very important for you to communicate early in the project exactly what your testing needs are so the criteria can be outlined and agreed upon by both parties. This helps sets your expectations to the manufacturer and they will be sure to include the relevant tests in your checklist.

While FATs can use simulations to demonstrate how the equipment will function in its future operating environment, it may be difficult to mimic the actual operating conditions. New equipment can be incredibly complex with countless opportunities for error. Fortunately, Original Equipment Manufacturers know better than to hope for the best – they plan for the best.

definition of factory acceptance testing

However, there could be an impact on the cleaning procedure that might be applied on-site. Making such changes at the installation site is impractical; hence, FAT is a must-do step versus nice to do, for critical systems. Any unsuccessful test runs or missing/incomplete documentation identified during TOP review is recorded onto a punch list and distributed to both the vendor and client management. The punch list mainly indicates the progress of the qualification activity. The punch list items can be addressed either prior to the FAT closure, or during the SAT execution, depending on its criticality. The vendor is considered to have delivered the product successfully if the FAT and SAT protocols are executed with all pending deliverables in the punch list closed.

acceptance testing

Site Acceptance Testing occurs at the customer’s test facility after the completed equipment is delivered to the customer site. These tests verify whether the equipment meets and/or exceeds the functionality and performance requirements written up by the customer themselves. They occur after all commissioning tasks for the equipment are completed but before installation. The customer specifies scenarios to test when a user story has been correctly implemented. A story can have one or many acceptance tests, whatever it takes to ensure the functionality works. Customers are responsible for verifying the correctness of the acceptance tests and reviewing test scores to decide which failed tests are of highest priority.

The focus is to consider FAT is more than a pressure test on the valves so a checklist has been provided for activities which should be done during FAT. Some of the applicable industrial standards such as API 598 and ISO 5208 are briefly reviewed in this chapter. FAT is generally the first stage definition of factory acceptance testing of system testing and should be witnessed by the customer period to the agreement for the machine to be delivered to the user site. The manufacture should ensure that a machine can pass the predefined test Prior to the witness acceptance testing so as to minimize the risk of any testing.

definition of factory acceptance testing

It is important to get the FAT officially signed off since this represents a major milestone in the overall project. The successful completion of the FAT serves as a benchmark for the system during site commissioning. Of the valves is normally done after assembling and before painting, mainly to make sure that the leakage rate from the body and the seats of the valve are within the accepted limits. This chapter provides practical examples of FAT on different types of valves.

The ISPE’s GAMP 5 guidance tells us that in a given project, there may be some pre-delivery testing that can include Factory Acceptance Testing. This testing requires that all system components be assembled and tested to show that the system functions as expected. A factory acceptance test is a test conducted at the vendor’s premises, usually by a third-party, to verify that the system operates according to the specifications. The client will eventually perform a site acceptance test upon proper installation at the permanent operation position. The SAT further verifies equipment performance in relation with other systems at the site. Today’s startup and commissioning environment requires many operations personnel, trades contractors, technicians, and engineers to be on hand during this scheduled event.

🟩 What is the reason for completing a Factory Acceptance Test?

These aspects primarily relate to functionality, safety, fitness to user requirements, compliance of the system to GMPs, and data integrity. It is common to find inconsistencies post fabrication since there are possibilities of misses during translation of all the user requirement specifications and purchase order commitments into design/fabrication. An example is the use of a typical coated surface instead of a stainless-steel finish for environmental chambers. The product impact could be minimal since it is strictly used for storage of the unit’s post-secondary packaging.

Maintaining the team until the CQV planned activities are complete is critical since much knowledge may remain tacit in a fast-paced commissioning scenario. Adequate mechanisms need to be in place within the CQV plan to document and convert the tacit knowledge into internal explicit knowledge at the earliest opportunity. Applying the insights discussed in this article can add value and greatly reduce potential downstream issues during a critical CQV project. The FAT should conclude with the user conducting a scripted test of the complete sequence of operations with programmers remaining as hands-off as possible. The script should be run through several times until a sequence can be run from start to finish with no problems encountered.

definition of factory acceptance testing

SafetyCulture ’s Analytics to continuously improve product quality and increase customer satisfaction. “Customers really enjoy our hospitality and overall support we provide during the process. Customers have shared their experiences elsewhere and said they’ve been dropped off at the site of the equipment and they fend for themselves. If they have any questions or concerns, we can address them in the moment and provide additional training,” he said.

Extended Factory Acceptance Test may be only applicable for several equipment or subsea structures, e.g., subsea trees with sub-assemblies. The System Integrity Test is performed to verify the whole system no matter from one supplier only or different suppliers, which shall interface with each other acceptably. The factory Acceptance test is not only beneficial for end-users and buyers but those manufacturing and packaging the product. The FAT helps assure both parties that the new equipment complies with all contractual specifications. Moreover, it helps address any functional issues before the equipment arrives at the client’s installation site.

Defining The Goals In A CQV Plan & Leveraging Checkpoints

If the oil pump does not turn on, I need to look into the wiring or my PLC logic. To test this I can change the current and look at the HMI installed on the panel to see if the indicator for the oil pump turns on. Assuming that other ends of these terminals here are connected to terminals number 1 and 2, to test this input I can put the signal simulator on the 4-20mA current mode and then connect it to the other end of these terminals. If you don’t know how to read and follow a PLC wiring diagram, you can read a previous RealPars article on this topic, How to Follow an Electrical Panel Wiring Diagram. You connect it to the circuit breaker only for testing and once you are done and want to ship the cabinet, you simply disconnect the wires from the topside of the circuit breaker.

Performance Testing – Run mechanical verifications, cross-reference with P&ID and electrical drawings. DE DIETRICH PROCESS SYSTEMS is the leading global provider of Process Equipment, Engineered Systems and Process Solutions for the fine chemical, chemical and pharmaceutical industry. Also confirm motor classification meets specified class and division standards. Times can vary depending on the complexity of the system and the corresponding FAT, but they are typically scheduled 2-4 weeks prior to the ship date to help maintain on-time delivery. The duration of the FAT can be anywhere from one day up to a couple of weeks. The more valuable input that is received from both parties, the more successful the test will be, which will help to facilitate a fast-track start up.

List of acceptance-testing frameworks

The factory Acceptance testing or FAT guarantees that the equipment is complying with all the requirements and are ready to be commissioned without any problem. This test is performed at the factory and is beneficial for both the end-users and the manufacturer. Any functional issues are identified before the equipment leaves the factory premise and can easily be rectified by the manufacturer. In engineering and its various subdisciplines, acceptance testing is a test conducted to determine if the requirements of a specification or contract are met. Factory Acceptance Testing helps verify that newly manufactured and packaged equipment meets its intended purpose. The FAT validates the operation of the equipment and makes sure the customers’ purchase order specifications and all other requirements have been met.

Compressor Key Safety, Environmental and Reliability Issues

Factory Acceptance Testing provides an efficient and cost-effective way to debug code before placing equipment in field commissioning, where any changes to code would increase costs and delay production. The FAT is performed by the client representative and/or consultants at the vendor’s facility or wherever the equipment is being fabricated. This could be of 2-day or 2-week long execution time frame, depending on the number, and the complexity of the equipment. While working on-site at the facility, it is important to adhere to their quality and safety standards. Vendors normally provide a tour of their facility, information on emergency exits and if required, train visitors on their specific safety procedures. Adequate Personnel Protective Equipment must be worn while observing or executing operational tests.

🟩 What is the difference between Factory Acceptance Testing and Site Acceptance Testing?

She usually writes about safety and quality topics, contributing to the creation of well-researched articles. Her 5-year experience in one of the world’s leading business news organisations helps enrich the quality of the information in her work. Williamson says feedback regarding the Sani-Matic pharmaceutical factory acceptance test process is overwhelmingly positive and he attributes a lot of it to the hospitality set forth companywide. There is a lot to cover in the whole pharmaceutical factory acceptance test process.

By documenting your configurations, you ensure that you have a record to check for changes later on if the system changes. However, GAMP tells us this type of testing is not needed for GAMP Category 3 or 4 systems unless they are brand new and extremely complex. Whether FAT is needed for Category 5 systems that are dependent on https://globalcloudteam.com/ the system type, novelty, and complexity. “It’s really one of the most involved and highest priorities that we do here at Sani-Matic. The entire team is available to provide any support needed during the entire process,” said Curtis Williamson, senior electrical project engineer who has been with the company for over 10 years.

Let’s say that this push button is connected to the first digital input of the PLC. To test this input, all you need to do is to press the push button and see if the LED light for the first digital input on the card turns on. To do a FAT you need to test each of the PLC inputs and outputs one by one and make sure everything works properly based on the PLC logic. So you have connected the power to the main circuit breaker and turned on all the devices on your panel. Although this seems a very simple process so far, there are two important points that you need to consider when trying to power on your control panel. A pressure switch is an electronic or mechanical device that informs that a certain set pressure is reached.

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