Across a multitude of industries, from manufacturing to aviation and from consumer goods to the tech sector, ensuring that the products meet precise specifications and customer expectations is pivotal. Herein lies the essence of the Factory Acceptance Test (FAT), a quality assurance process that acts as the keystone of effective production. In this blog post, we aim to decode FAT, illuminating its significance, procedures, and benefits.

What is a Factory Acceptance Test (FAT)?

A Factory Acceptance Test is a major project milestone where a product is tested to confirm that it operates according to its design specifications and fulfills the intended purpose for which it was built. The primary objective of FAT is to verify the product’s functionality, construction, and integrity at the manufacturer’s site, before it gets shipped to the customer or end-user.

The FAT procedure typically includes a mix of visual inspections, functional tests, and document checks to ascertain that the product aligns with the design and operational requirements. It provides an opportunity for the customer or their representatives to be satisfied that the product being purchased is what they have specified and paid for.

How does FAT work?

The FAT procedure varies depending on the product type, industry, and specific customer requirements. However, a general FAT process would involve the following steps:

• Preparation: Prior to the test, a detailed FAT plan is developed. This includes the creation of test procedures that align with the customer’s specifications and a schedule for conducting the test.
• Inspection: This involves visual and physical inspection of the product to ensure it is built according to design requirements and is free from defects.
• Functional Testing: The product is tested under different conditions to ensure that it performs as expected. This could involve running the product at full capacity, testing its safety features, or evaluating its performance under simulated real-world conditions.
• Document Verification: This includes checking all relevant documentation to ensure that it matches the agreed-upon specifications. The documents might include design blueprints, manuals, certificates, and test results.
• Customer Approval: If the product passes the FAT, the customer or their representative signs off on the test, indicating their satisfaction with the product’s performance and confirming its readiness for shipment.

When should FAT be used?

Factory Acceptance Testing (FAT) is suitable for inclusion in the sourcing process when the purchased equipment is complex, critical to operations, or has stringent performance requirements. It is particularly useful for verifying that the equipment meets technical specifications, safety standards, and operational functionality before it is shipped to the site. FAT is commonly used for large capital equipment, machinery, or systems with custom configurations, where defects or non-compliance could lead to costly downtime, safety risks, or rework.

However, FAT may not be necessary for standard, off-the-shelf products, or low-risk components where the reliability is already well established, and the cost or time involved in testing would outweigh the benefits. For such items, inspection and quality certification might suffice.

Why is FAT Important?

FAT serves several key purposes:

• Quality Assurance: By detecting any discrepancies or non-compliance before the product reaches the customer, FAT allows for rectification of issues at an early stage, ensuring the delivery of a high-quality product.
• Cost and Time Efficiency: FAT can save both time and money by preventing the shipment of a faulty or non-compliant product, avoiding the costly implications of product recalls or reworks.
• Enhanced Communication: FAT fosters better communication and understanding between the manufacturer and the customer, leading to a collaborative environment that benefits both parties.
• Customer Satisfaction: A successful FAT process assures the customer that the product they are receiving is precisely what they ordered, enhancing customer satisfaction and trust.

The Role of Factory Acceptance Tests (FAT) in the Aviation Industry (sample case)

“In the bustling world of the aviation industry, where I serve as a PMQA (Procured Material Quality Assurance) and work closely with a professional buyer, precision, and consistency are our topmost priorities. As we’re particularly involved in the production of Unmanned Aerial Vehicles (UAVs), the validation of the manufacturing process is crucial. This validation is often achieved through Factory Acceptance Tests (FAT), as per the EN 9102 standard, which is the topic of below:

What is EN 9102?

EN 9102 is a European standard developed by the European Committee for Standardization (CEN). It specifically addresses the aviation, space, and defense industries, providing guidelines for comprehensive quality assurance. The standard is primarily aimed at First Article Inspection (FAI) – a detailed evaluation of product design, manufacturing process, and assembly to ensure that the production methods reliably yield a product that meets predetermined quality parameters.

The Core Idea of Factory Acceptance Tests

Factory Acceptance Test (FAT) represents a significant part of the EN 9102 standard. In essence, FAT is a process in which the customer tests the equipment or product, while still at the manufacturer’s facility, to confirm that it operates and is built according to design specifications before shipment.

By performing FAT, we ensure that the UAVs produced meet the defined criteria and specifications, thereby saving time, reducing costs, and upholding customer satisfaction.

FAT in UAV Manufacturing

Let’s dive into a practical example. Suppose a company in the defense sector contracts our firm to manufacture a fleet of UAVs designed for surveillance purposes. They would provide a set of requirements, including flight time, payload capacity, communication range, and specialized equipment such as infrared cameras for night operations.

Once the prototype UAV is manufactured, the customer or their representative would conduct a Factory Acceptance Test at our premises. This could include examining the physical build quality, testing software and control systems, flight testing for performance validation, and verifying compliance with safety standards. The FAT allows us to correct any issues before mass production, thus ensuring all UAVs shipped meet the agreed-upon specifications and standards.

The Significance of FAT

The FAT process offers many benefits, primarily revolving around error prevention and cost optimization. By spotting any discrepancies or non-compliance at the manufacturing stage, we avoid unnecessary expenditures and resource wastage that would occur if these problems were to be discovered later.

Moreover, FAT strengthens communication between the manufacturer and the customer. It gives the buyer an in-depth understanding of the product’s functionality, and the manufacturer receives a clearer picture of the customer’s expectations.

Standards that include FAT

The following is a list of standards that include or refer to a Factory Acceptance Test procedure:

• IEC 61511: International standard for safety systems in the process industry sector. It includes FAT as part of the validation of safety instrumented systems.
• ISO 9001: The international standard for Quality Management Systems (QMS). While it doesn’t explicitly mention FAT, it emphasizes the concept of verification and validation processes, under which FAT is generally conducted.
• IEC 60204-1: This international standard relates to the safety of machinery – electrical equipment of machines. It includes requirements for Factory Acceptance Tests.
• ANSI/ISA-S88.01: A standard for batch control from the International Society of Automation (ISA). This standard calls for Factory Acceptance Testing in the context of process control systems.
• ISO 13485: An international standard for Quality Management System (QMS) specific to medical device industry, it necessitates FAT for verifying that the equipment meets the specified purchase requirements.
• EN 50128: European standard for railway applications, it describes procedures and technical requirements for the development of software, including the use of FAT.
• EN 60947-6-2: The European standard for low-voltage switchgear and controlgear, it includes requirements for the Factory Acceptance Test for transfer switching equipment.
• EN 61010-1: Safety requirements for electrical equipment for measurement, control, and laboratory use, it necessitates a set of FATs.
• ASME B31.1: This is the American Society of Mechanical Engineers (ASME) standard for power piping systems. It calls for Factory Acceptance Testing of systems before implementation.
• IEC 62443-2-4: This standard for Industrial communication networks – Network and system security includes FAT as a part of the system integration process.

Wrapping Up

To sum up, Factory Acceptance Tests are a crucial step in the production process, regardless of the industry. They serve as a quality checkpoint, a confirmation of the product’s readiness, and an assurance of the manufacturer’s commitment to delivering what has been promised. By bridging the gap between the manufacturer’s assumptions and the customer’s expectations, FAT helps in building a relationship founded on trust, reliability, and quality.

In the UAV manufacturing landscape, the EN 9102 and its FAT principles form a crucial part of our commitment to quality and reliability. As an integral part of our manufacturing process, FAT allows us to deliver high-quality, precise, and reliable UAVs that meet our customers’ exact needs. Furthermore, it’s a testament to our dedication to deliver top-tier products, helping to build stronger and lasting relationships with our customers.

When applied, FAT is an integrated part of the Sourcing process. Learn more about a standard sourcing process in the course Package: The Sourcing Engine.

The Sourcing Engine is build on three courses presenting the basics of a modern sourcing process. Learn about the key activities when preparing, negotiating and implementing a new improved supply chain.

Note: Illustration to the blogpost was created by CHAT-GPT.