Factory Acceptance Testing (FAT) - An Essential for Optimum Delivery

Delivering quality and exceeding the expectations of our clients is always a requisite at Cybernetik. Factory Acceptance Testing or FAT is one of the project milestones that helps us meet our goals and ensure smooth functionality of the system through its entire lifecycle. Systems that go through rigorous FAT enable our clients to achieve optimum productivity and be the frontrunners in their respective industry.

What is FAT?

Prior to the delivery and shipment of any automation system, we build the entire system at Cybernetik, just as it would have been built at the client’s place and perform a comprehensive scrutiny, also known as Factory Acceptance Testing or FAT.  

This scrutiny includes checking the system for a number of factors like Functionality, SLA adherence, Legal & Compliance accuracy, P&ID and quality certifications. Going further, at Cybernetik we also prepare the system for Key Performance Indicators (KPIs) such as production rate (cycle time), process flow, user interface, workmanship and safety.

When is FAT performed?  

FAT is performed before we dispatch the system from Cybernetik. It helps us ensure quality and safety of the system. It also saves on time and cost. Issues can be identified and rectified while the system is still in our factory. This reduces the initial hassles while setting up the system at the client’s place and reduces the time to make it run smoothly and to its full capacity. In addition, it gives client a clear idea of the physical layout and if there is a need for alterations and reconfigurations, they can be implemented prior to the delivery.

Who should be present during FAT?

To ensure the success of FAT, we recommend the presence of personnel from client’s side on the shop floor. The personnel could be Project Managers, Operators, Plant Engineers and Maintenance Engineers. This helps everyone understand the environment where the system is being tested enabling better troubleshooting in case of breakdowns during run-time.

Why is FAT important?

FAT helps identify non-conformities in the system while the system is still at Cybernetik, so that problems can be addressed before installation of the system. This offers more flexibility to our technical experts for providing optimal solutions, without affecting the project timelines. FAT also eliminates ambiguity around the KPIs set for the equipment.

Though Cybernetik incurs considerable costs simulating real-time shop environment for the system to be appropriately evaluated, this lowers the risk of breakdowns during shop time as well as the need for repetitive servicing. At Cybernetik, FAT is not billed to the client separately, as it is included in the scope of delivery established earlier. We clarify and lay down the requirements and measures that will compose a customised FAT, and these are carefully implemented to ensure the success of FAT.

Just like before delivering any product, the manufacturer checks it for quality, FAT is performed before the shipment of automation equipment to ensure its quality standards and full functionality. It is also important for ensuring safety of equipment and personnel. After all, creating safer workplaces is one of the most important aspects of industrial automation. Click here to read more.

FAT is a standard procedure that helps us deliver robust and consistent results and enables our clients to gain optimal benefits from Cybernetik systems. Contact us to know more about how you can optimize your processes through automation systems from Cybernetik.

View all blogs

Streamlining a Food Factory with Automation

Food industry is one of the most demanding industries and often requires near perfection and consistency to survive and thrive. Consumer requirements like higher quality standards, lesser costs, more accountability, more product variety as well as industry requirements like regulatory compliances, ability to meet increasing labour costs and sustainability pose the challenges for food processing companies. Processes in the food industry were traditionally considered difficult to automate. Robotic automation has made its mark in agriculture eliminating several back-breaking tasks for the farmers. However, as food moved down the production line in a factory, automation would take a backseat. But in the last few decades, as technology advanced and food companies started realizing the benefits of automation, this scenario changed and automation slowly but gradually started making its strides in the food industry. It streamlined the industry in several ways and helped tackle many challenges faced by the industry. Quality & Safety  Food industry is one of the most quality-sensitive industries. Even a single instance of contamination can significantly affect sales and impede business growth. Automation provides a reliable solution to fulfill the quality and safety requirements in the food industry. Automated food processes are easier to standardise and the chances of deviation from the standard process are considerably reduced. Automation eliminates the possibility of contamination caused by human intervention. Faulty products can be more easily isolated and prevented from entering the marketplace. Automation can also help in maintaining a uniform taste throughout the production process. The demand for different variants of a product can be fulfilled by bringing in more flexibility in the automation systems. Enhanced Traceability  Automation makes it easy to track down a product from the start to the end of the production line. Enhanced traceability helps maintain the product quality and companies are better equipped to protect their brand. Consequently, it also reduces the cost of regulatory compliances. More Storage Space End-of-line automation systems like palletisers help in better utilization of the available storage space. Smart methods like matrix formation and utilization of vertical space result in increased storage capacity for factories. This helps in inventory management and scaling up production capacity. Creating Safer Work Environment  Food production when carried out on industrial scale can be potentially dangerous to humans. Industrial applications like deep frying, boiling, cutting and peeling make employees risk their life and limb. Automation helps in shifting humans from harmful tasks to safer work environments. Starting the Process of Automation As companies decide to automate, they have several questions. One of the main concerns is flexibility that is needed. But some processes like mixing, bagging and palletising are indeed generic and can be easily automated. Along with the companies that opt for complete automation, there are as many companies that decide to take a hybrid approach. Cybernetik offers both turnkey solutions and individual systems for automating specific processes. Get in touch with us to know more.

Read More

Implementing Automation Through Project Management Approach

Acquiring and implementing state-of-the-art automation systems in a manufacturing company poses multiple challenges with the varying levels of difficulty. Some of these challenges can be so daunting that they become a main reason for companies to delay the decision of getting advanced technologies. Implementing automation with a project management approach is one of the best ways to tackle these challenges. Through project management, we are able to predict the timelines, costs, performance, ROI and other important metrics. This can help companies in making the important decisions like whether they should go for an end-to-end solution or an automation system for a specific operation. Project management also helps in proper execution and delivery of the project so that our clients can get the best returns on their investment. The main stages in the lifecycle of an automation project are explained in the infographic over here. Click the image on the left to see the complete infographic. Our project management approach makes it easier for you to take the right decision at the right time. Whatever your requirements, Cybernetik can provide you with end-to-end services starting from project initiation to after-sales maintenance and support. Here are some Case Studies of the projects that we have implemented. Communicate your requirements and let us figure out the best course of action for your company to benefit from the advanced automation technologies.

Read More

Hiring: Technical Proposals & Marketing Engineer

Get in touch if you fulfill the following requirements and wish to work on exciting projects in industrial automation. Education: DME / BE or equivalent. Experience: 2-3 years in Industrial Automation in Automobile/Food/Chemical/Pharma industry. Technical Knowhow: Conveying systems, packaging systems, robotic systems and applications, pneumatic and hydraulic systems. Languages: English, Hindi and Marathi (spoken & written) Willing to travel across India. Work Profile: As a Technical Proposals & Marketing Engineer, you need to handle the following and other related job responsibilities. 1. Visit client sites with the marketing team for understanding requirements, feasibility study, input data collection and capture site details.2. Prepare layouts on 2D/3D CAD software.3. Write technical proposals as per standard templates.4. Study existing systems and suggest improvements, if any.5. Handle costing and purchase of items and collect technical data from the respective supplier. 6. Collect commercial offers from sub-vendors (mainly bought-outs).7. Collect data of previous projects from ERP systems and verify from the respective project / design person. 8. Interact with the project person to verify technical and commercial aspects of the requirement. 9. Interact with the design department and verify the parameters suggested to the client before submitting the quote.10. Standardize quotations, costing and revisions as per client requirements. Send your resume to: career.automation@cybernetik.com

Read More

Get in Touch

Retype the CAPTCHA code from the image
Change the CAPTCHA codeSpeak the CAPTCHA code

Cybernetik Technologies is an Indian industrial automation company that designs, builds and installs turnkey automation systems to address the material handling and processing needs of the agro process, food, automotive and environment sectors. Our expertise lies in providing innovative solutions for conveying, processing, robotic handling and end-of- line packaging. We are a single source solution for all automation requirements by providing services ranging from concept generation to installation, commissioning and after-sales support.

Copyright 2016 | Cybernetik Technologies Pvt. Ltd.