Top 5 Factory Acceptance Test Checklists

Easily resolve equipment nonconformities and prevent costly project delays

Streamline factory acceptance tests using iAuditor digital checklist app

A Factory Acceptance Test (FAT) 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.

Using a factory acceptance test checklist can reduce costly project delays by ensuring the completion of FAT protocol, such as standard work procedures, certificates of compliance and welding processes qualifications. This article features:

  1. Effective countermeasures to 4 common FAT issues
  2. iAuditor digital checklist app to streamline factory acceptance tests
  3. Free factory acceptance test checklists you can download, customize and use

Click here to download Top 5 Factory Acceptance Test Checklists

Overlooked equipment discrepancies can lead to installation problems onsite which can wreak havoc on a project schedule. Prior to shipment, quality managers should resolve nonconformities at the factory so that the clients’ new processing lines are up and ready to go on time. Here are 4 common issues discovered from factory acceptance tests and what countermeasures quality teams can apply to ensure equipment reliability.

Issue #1: Poor Machine Quality or Craftsmanship

Quality managers should regularly coordinate with design engineers and fabrication managers to ascertain that the as-built technical drawings (electrical, mechanical, pneumatic and process schemes) are followed. Before the factory acceptance test, prepare the instruments calibration certificates and refer to the equipment and materials data sheets to deliver high quality machines with performance that clients can trust.

Issue #2: Nonconformity to Regulatory or Sanitary Specifications

Clients often specify a level of standard in manufacturing the equipment they ordered. Bioprocessing equipment, boilers and pressure vessels can receive American Society of Mechanical Engineers (ASME) certifications through conformity assessments. For electric and electronic products, systems and services, manufacturers generally adhere to International Electrotechnical Commission (IEC) standards. Quality managers can also consider collaborating with industrial hygienists or health and safety officers to comply with design specifications.

Issue #3: Lack of Appropriate Machine Guarding and Labels

Conduct pre and post operation checks of machine guards before and during FAT with clients. It is the responsibility of the quality manager to provide installation, maintenance and users’ manuals, recommended spare parts lists, and easy-to-use training materials for operators and maintenance personnel. The Lock Out Tag Out (LOTO) labels and procedures should also be clearly stipulated to comply with Occupational Health & Safety Administration (OSHA) standards.

Issue #4: Lower than Expected Throughput

Quality managers should present a step-by-step FAT procedure, including all records of the agreed FAT protocol, to the client for review and approval. On the actual factory acceptance test, the desired functionality of the equipment should be proven through a series of validation tests based on a consensus acceptance criteria and punch list (compilation of nonconformities for modification).

When quality managers resolve the punch list and clients accept the working condition of the equipment at the factory, they should eventually perform a site acceptance test (SAT). Upon proper installation at the permanent operation position, the SAT verifies equipment performance in relation with other systems at the site.

iAuditor Digital Checklist App

Use iAuditor, the world’s most powerful digital checklist app, to streamline factory acceptance tests, ensure equipment reliability and prevent costly project delays. With iAuditor, you can:

  • Use FAT checklists offline or online
  • Capture photo evidence
  • Assign actions for nonconformities
  • Gather digital signatures
  • Automatically share FAT reports
  • Gain actionable insights
iAuditor Digital Checklist App

To help you get started, here are 5 of the best factory acceptance test checklists you can download and customize for free.

Top 5 Factory Acceptance Test Checklists

1. Factory Acceptance Test Checklist

A Factory Acceptance Test (FAT) checklist is used by quality managers to keep a project on track and within its budget by resolving equipment nonconformities prior to shipment. This FAT checklist has been designed to make it easier for quality managers to perform factory acceptance tests in the manufacturing facility and prevent costly project delays. Use iAuditor to efficiently perform the following:

  1. Document the complete/incomplete FAT protocol
  2. Capture photo evidence of the entire FAT procedure, including hazard identification, safety inspection and ergonomic assessment
  3. Specify the pass/fail acceptance criteria upon the actual FAT
  4. Assign corrective actions for equipment nonconformities
  5. Validate the factory acceptance test with digital signatures of the FAT personnel

2. Factory Acceptance Template

This factory acceptance template is a comprehensive validation test for outboard equipment (external effects unit), including AC Power Test, Audio Test, Video Test, Control and Performance Test, and Network Test. Quality managers in the manufacturing facility can customize this template based on the specifications of the equipment to undergo a factory acceptance test. You can also use this factory acceptance template to perform systematic visual inspections and proper documentation of FAT protocol.

3. Site Acceptance Test Checklist

A Site Acceptance Test (SAT) is the process of validating the reliability of newly manufactured equipment with other interfaces at the site. After the factory acceptance test, equipment delivery and site installation, the client conducts a site acceptance test ideally with the quality manager from the manufacturing facility. Use this checklist as a guideline in conducting site acceptance tests and automatically generate a shareable report the moment you finish the SAT.

4. Manufacturing Quality Control Checklist

A manufacturing quality control checklist is a tool used to help maintain standards by evaluating the quality of a product through weekly visual inspections of its size, color, weight, the materials used and packaging. Schedule a quality control check and send real-time notification to quality control teams using iAuditor. Easily identify trends in manufacturing processes with iAuditor’s Analytics to continuously improve product quality and increase customer satisfaction.

5. Manufacturing Facility Inspection Checklist

A manufacturing facility inspection checklist is used by trained officers to ensure the health and safety compliance of manufacturers daily. Easily inspect the tools and machinery, machine guards, ladders and platforms/elevating devices, sound level/noise, and loading/unloading racks in a manufacturing facility. With iAuditor mobile inspection app, you can easily secure fire emergency procedures, materials handling and storage, personal protective equipment and training of workers. All data is automatically saved and stored in the cloud!