Factory acceptance testing is a process carried out by a manufacturer or supplier before they deliver plant, machinery or equipment to the customer. It involves a series of tests and inspections to ensure the product meets the specified requirements, design criteria, and functionality.

The purpose is to prevent issues at the customer’s site by checking the system meets all agreed-upon specifications and rectifying any manufacturing issues before deployment. It also allows customers to see the product in action before accepting delivery.

What’s the difference between a factory acceptance test (FAT) and a site acceptance test (SAT)?

A factory acceptance test (FAT) is conducted by the manufacturer (either at their factory or another suitable location). A site acceptance test (SAT) takes place at the customer's site after the system has been delivered and installed.

The goal of both is to determine whether a new piece of equipment will function as needed.

Because the FAT takes place at the manufacturer’s facility, it may be difficult to simulate both the production volume and the conditions of the customer’s product, especially if the product requires packing at a certain temperature, consistency or speed.

Therefore, the FAT will identify any manufacturing issues and ensure specifications are met, but the SAT will simulate how the machine responds under actual factory conditions. It will also confirm that the plant or machine has been properly installed and is fully operational.

Benefits of a factory acceptance test

Factory acceptance tests are beneficial for both the manufacturer of the equipment and the customer. A factory acceptance test will help you:

• Achieve independent proof of functionality, quality and integrity
• Verify all important documents, such as manuals, instructions, plans, drawings, piping and instrumentation diagrams
• Ensure that equipment performs as expected under the testable range of conditions, including handling errors
• Allow you to view the machinery in operational mode before shipping
• Provide the opportunity for initial hands-on training
• Determine the required and recommended spare parts
• Review maintenance procedures and equipment limitations
• Determine additional issues that need to be addressed before shipping
• Catch defects early to prevent costly downtime and disruptions after installation
• Verify compliance and minimise safety hazards by ensuring the equipment adheres to all relevant safety regulations
• Reduce the risk of disputes by providing clear documentation and verification that the equipment meets expectations
• Ensure a smooth transition and a less error-prone installation process, leading to faster operational readiness
• Minimise the need for post-installation troubleshooting and adjustments

How to conduct a factory acceptance test

The exact process of a factory acceptance test will depend on the type of equipment and the performance criteria. However, it should generally involve the following steps:

Planning your test

The first step is planning. This is where you determine what is being tested and which requirements and performance criteria must be met. What are the agreed-upon specifications, functionalities, and performance metrics? Who will be present during the testing process (manufacturer personnel, inspectors, and customer representatives)?

Setting up the test environment

Before carrying out the test, you’ll need to set up the necessary infrastructure for the test, including the required software and hardware. Ensure all necessary tools, gauges, and measurement equipment are calibrated and accessible. Collate all relevant documents like drawings, data sheets, certifications, factory inspection plans, and safety procedures. Carry out a risk assessment and ensure safety protocols are in place.

Visual inspection

Start with a visual inspection of the equipment, checking it meets specifications, doesn’t have any visible defects or damage, and is free of dirt and debris. Confirm components are labelled correctly and safety features such as guards and emergency stops are in place.

Functional, operational and performance testing

Carry out tests to ensure the machinery meets the agreed-upon specifications and performs to expectations. Assess the performance under simulated operating conditions. Test individual components, the control system, any alarms and data monitoring systems. Ensure compliance with electrical safety regulations and be aware of any mechanical hazards or noise emissions.

Documenting the results

Document all observations and test results. You might find it beneficial to take photos, make voice recordings, or film the tests to use as supporting evidence. Compile all test results, observations, and photos into a comprehensive FAT report. Include details of any issues you have identified and any recommendations.

Completed FAT protocol:

• User and maintenance manuals
• Training materials
• Standard work procedures
• Standard maintenance procedures
• Recommended spare parts lists
• Certificates of compliance
• As-built technical drawings
• Materials certificates and data sheets
• Main equipment data sheets
• Instruments calibration certificates
• Welding processes qualifications

Rectifying issues

Any problems, faults or defects identified during the factory acceptance test should be rectified before the product is shipped to the customer.

Get expert support with your FAT or SAT

AES are dedicated to supporting manufacturing businesses and we can assist you with the planning and implementation of your factory acceptance tests and site acceptance tests.

We are fully qualified and competent in carrying out the installation, testing and inspecting of industrial electrical equipment and machinery. Our industry accreditations include NICEIC, CHAS, SafeContractor, CompEx, IPAF and PASMA.

If you are purchasing machinery or equipment for your factory and would like us to be present during the factory acceptance test or would like us to safely install the equipment for site acceptance testing, get in touch.