FAT and SAT Checklist for a Rigid Box Production Line

Factory Acceptance Testing and Site Acceptance Testing are not ceremonial project milestones. They are controlled demonstrations that the supplied line, documentation and operating process meet the agreed requirements.

The best acceptance plans are prepared before the machine is built. They define products, materials, measurements, responsibilities and pass criteria while corrective action is still practical.

Before FAT: freeze the acceptance basis

Create a single approved document that references the commercial scope, technical specification, line layout, utilities, product matrix and exclusions. Every test should trace back to a requirement. Ambiguous phrases such as “good quality” or “high speed” must be replaced by measurable criteria.

Confirm who supplies boards, papers, adhesives, inserts and samples. Materials should represent normal production, including known difficult combinations.

1. Machine and scope verification

• verify model, modules, options, tooling and change parts;
• check line direction, access areas and operator stations;
• confirm installed electrical and pneumatic components;
• review manuals, drawings, declarations and spare-parts lists;
• record open items before functional testing begins.

2. Safety and compliance functions

Test guards, interlocks, emergency stops, safe access points, reset logic and restart behaviour. A safety circuit should be tested intentionally; visual inspection alone is insufficient. Record the devices tested and the result.

3. Representative product matrix

Choose products that exercise the real process envelope:

• a frequent production format;
• a small or delicate format;
• a large or deep format;
• a difficult material or finish;
• a geometry requiring a specific process capability.

Do not use only the easiest demonstration product. The purpose is to reduce project risk, not to create a visually smooth visit.

4. Output and stability test

Define the measurement window, required rate, permitted stops and acceptable output. Separate gross cycles from accepted boxes. A useful report records produced quantity, rejected quantity, stop reasons, material used and the operating crew.

Where a target depends on material or geometry, document the tested conditions clearly so the result can be reproduced.

5. Quality verification

Agree how quality is measured and by whom. Depending on the product, criteria may include centring, corner definition, edge turn-in, dimensional tolerance, surface cleanliness, adhesion and visual defects. Use approved reference samples when appearance cannot be described by dimensions alone.

6. Changeover and recipe repeatability

Measure the transition from the last accepted box of one format to the first accepted box of the next. Include material preparation, mechanical changes, recipe loading, first-piece approval and any scrap generated.

Then return to a previously tested format. This second step verifies whether stored settings and adjustment procedures are repeatable.

7. Alarms, recovery and diagnostics

Introduce representative faults safely and verify that messages identify the problem, the machine reaches the intended state and the operator can recover through the documented sequence. Test loss and restoration of utilities where appropriate.

8. Software, recipes and data

• verify user roles and access levels;
• save, recall and protect format recipes;
• review backup and restore procedures;
• confirm production counters and required interfaces;
• document installed software versions.

9. Training and maintenance readiness

Acceptance is incomplete if the machine works only with the supplier’s specialist present. Operators should demonstrate normal start, production, stop, cleaning, changeover and fault recovery. Maintenance personnel should understand inspection points, lubrication, safety procedures and backup management.

SAT: repeat the critical evidence on site

The SAT confirms the line after transport, installation and connection to the customer’s environment. Verify utilities, layout, integration, safety, representative products and training. Differences between factory and site materials should be documented rather than absorbed into an undefined ramp-up phase.

Close with an evidence package

The final acceptance record should contain test sheets, measured results, approved deviations, open-item ownership, due dates, software backups and signed documents. This package becomes the baseline for future service and performance discussions.