Why the FAT matters
A factory acceptance test, or FAT, is a structured test of a machine or system at the manufacturer's works, before it is packed and shipped. For buyers in Saudi Arabia and the Middle East ordering equipment from Germany, it is the last practical opportunity to find and fix problems close to the people who built the machine.
The same principle applies to complete production lines and to individual units such as boilers, compressors or packaging machines. Where several suppliers deliver parts of one line, an integrated test of the interfaces between them is worth arranging, even if only for the critical connections.
Once a machine has crossed the sea, every correction becomes slower and more expensive. A missing function, a wrong voltage or an incomplete document that takes a day to fix in Germany can take weeks to fix on site. A well-run FAT protects the schedule, the budget and the start of production.
Prepare the FAT protocol early
The FAT should be defined in the purchase contract, with a written protocol agreed well before the test date. The protocol turns the technical specification into a list of checks that both sides accept as the basis for approval.
- The scope: which machines, modules and software are tested
- The test conditions, including materials, speeds and durations
- Measurable acceptance criteria for output, accuracy and quality
- Who attends from the buyer and the supplier, and who signs
- How deviations are recorded, classified and closed
Where possible, test with your own raw materials or samples that match them. A machine tuned on the supplier's standard material may behave differently with the material it will process in your plant.
What to check on the day
A thorough FAT covers the machine as a whole, from its mechanical build to its controls and safety systems. A practical checklist usually includes the following.
- Visual and mechanical inspection: build quality, welds, finish, materials and agreed components
- Conformity with the order: brands of motors, drives, PLCs and sensors as specified
- Electrical data: voltage and frequency for your site, including 60 Hz where needed, cabinet layout and labelling
- Function tests of every operating mode, including start, stop, emergency stop and fault recovery
- Performance runs at rated speed, with output and quality measured against the criteria
- Safety devices, guards, interlocks and warning signs, with labels in the agreed languages
- Climate suitability, such as cabinet cooling and protection ratings for hot, dusty conditions
Run the machine long enough to see stable behaviour. Short demonstration runs can hide problems such as overheating, drift or intermittent faults that only appear after an hour or more.
Documentation and software
Documentation is part of the delivery and should be checked at the FAT with the same care as the machine. Confirm that operating and maintenance manuals, electrical and pneumatic schematics, parts lists, certificates and declarations are complete and in the agreed languages.
For software, make sure the version tested is the version that ships. Request backups of PLC and HMI programs, drive parameters and recipes, and agree how source code and future updates will be handled. A recommended spare parts list, reviewed against the conditions at your site, is also worth settling now.
After the FAT: punch list, packing and SAT
Few FATs end with no findings. The usual outcome is a signed report with a punch list of open items, each with a responsible person and a deadline. Major items should be fixed and retested before shipment. Minor items may be closed on site, if both sides agree in writing.
Link payment milestones to the FAT where the contract allows, so that release for shipment follows a successful test. Inspect the packing as well, including crate marking and lifting points, since protection for sea freight and long storage in a hot climate matters as much as the machine itself.
The FAT is followed by a site acceptance test, or SAT, after installation at your plant. Using the FAT results as the reference makes the SAT faster and helps separate transport or installation issues from build issues.
Common mistakes to avoid
- Agreeing the protocol only days before the test
- Sending attendees who do not know the process or the specification
- Accepting a short demonstration in place of a full performance run
- Leaving documentation and software checks for later
- Shipping with major open items to save time
Wavy Solutions sources machinery from German and European manufacturers and supports buyers through FATs, logistics and installation. We can help you prepare the protocol and attend the test on your behalf.