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.

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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

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Innovative Technique in Agro Processing: Supercritical Fluid Extraction (SCFE)

Innovations in food processing industry are comparatively slow, as safety and quality are always the primary concerns. Supercritical Fluid Extraction System from Cybernetik fulfills these criteria and provides a safe and profitable solution for the agro-processing industry. What is Supercritical Fluid Extraction process? SCFE is one of the recent techniques used for agro processing. It is used primarily for decaffeination of tea / coffee, fractionation of polymeric materials, and extraction of oils, oleoresins, flavours, fats, spices and many other ingredients. When a substance is heated and pressurised above its critical point, it transforms into its supercritical state, where it is neither liquid nor gas. In this particular state, a substance can effuse through solids like a gas and dissolve materials like a liquid. Thus, it becomes a powerful medium for extraction of ingredients from raw materials.  Why CO2 is a preferred fluid for SCFE process? Carbon dioxide in its supercritical state is non-toxic, non-flammable and chemically inert. It also provides higher extraction efficiency and is ideal for high value extracts. There is no need for solvent removal. As CO2 is considered safe for humans, it is a preferred supercritical fluid in agro and food processing. Why use SCFE system from Cybernetik? Cybernetik’s SCFE system provides higher extraction efficiency, high product purity, consistent product quality and prolonged product shelf life. It is easy to clean and maintain and significantly reduces the operating costs. The system uses USFDA approved process for extraction of ingredients from organic raw materials in agro-processing industry. The system consists of high pressure and heating system, where liquid CO2 is transformed into supercritical CO2. The supercritical CO2 is mixed with the raw material in the extraction vessel. The mixture is further transported into gas-liquid separation chamber, where supercritical CO2 transforms into gas and is easily separated from the extract. This gas CO2 can be conveniently reused for further process. Using Cybernetik SCFE systems can offer several other benefits in your industry. Know more about SCFE system and other agro-processing solutions from Cybernetik.For further information, contact our representatives.

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Creating Safer Workplaces through Industrial Automation

Safer working environment for humans is one the biggest boons of automation. Everypassing day, innovative automation systems are being created all over the world to keephumans away from dangers. These dangers might pose an immediate risk to the life or bodyparts of humans or they might be in the form of tasks which put human health at risk if theycarry out these tasks over a long term. Here is how automation can help in eliminating thesedangers.Preventing loss of life or body partsIn automotive manufacturing, press shop is one of the most accident prone areas. There areinnumerable cases where operators have lost their fingers or even hand while working withthe press machine. In fact, in one of the unfortunate accidents, a maintenance operator losthis life while doing the routine maintenance of a press machine.Press machines require an extremely high level of eye-hand / foot coordination. Not tomention, the machines are absolutely unforgiving of mistakes. A single blink of an eye andthe operator can lose a precious part of his body. Press loaders and unloaders fromCybernetik can help manufacturers keep workers away from this accident prone area andmake the workplace safer for them.Eliminating cumbersome tasksCertain industrial tasks need to be done and need to be done at a specific speed to continuethe production line without being interrupted. This is also necessary to achieve economies ofscale in price-sensitive markets like automotive manufacturing or FMCG products like snackfood items.Such tasks and their speed requirements make them too cumbersome for humans. Imaginea shop floor worker lifting and moving a 100 kg bag several times a day. It not only puts theworker’s health and safety at risk, it also negatively affects the manufacturing line as humanswill inevitably work at reduced speed after some time. This creates a bottleneck in thesystem, which can be easily and efficiently avoided through automated systems like roboticpalletizing.Production of food items may not be an obviously risky or unsafe process. However, whenfood items are produced on the industrial scale, it can quickly transform into a cumbersometask. Take the example of a worker who is working in a factory that produces savoury friedsnacks and who has to deep fry the food items. He needs to work in the dangerous vicinityof an enormous quantity of boiling oil. Besides, the fire and heat also pose the risk ofdehydration.Apart from this, the highly repetitive task can quickly become a boring chore for humans.Bored humans may or may not follow the standard procedure while doing the task. This notonly puts humans in the close vicinity of a danger, it might also lead to the production ofsubstandard quality food items, which again becomes a health risk for consumers. Snackfood automation helps in avoiding these risks, making human resources available for moreskilled tasks.Keeping humans away from hazardous materials and environmentsIn industrial manufacturing, humans need to work with all kinds of materials. Some of themare not safe for humans and might put their health at risk. For example, there might behazardous chemicals, which need to be packed in bags. Exposing humans to thesechemicals might put their health at risk in the long term or sometimes even in the short term.Automatic bagging systems help in eliminating this risk.In certain cutting tasks, the dust produced during the process is harmful for humans. Itbecomes a health risk for them when it enters their eyes, mouth or nose. To prevent this,completely automated systems are designed, which are then covered with a canopy so thatthe dust does not get spread into the atmosphere.There are several such examples of automation systems that help prevent or reduce safetyrisks to humans in different industries. Cybernetik can work with you to design and createautomation systems to enhance safety in your industry. Get in touch with us to know more.

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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.