Acceptance criteria, delivered configuration, test evidence, punch-list closure and shipment release
Bottom line: A leveling machine factory acceptance test is a documented comparison between the machine offered for shipment and the approved project requirements. It should identify the exact machine and configuration, demonstrate agreed functions, record any representative-material test and measurement method, close deviations, and confirm the document and packing package. A generic list of fixed tolerances cannot replace the signed FAT protocol.
Which documents define the FAT pass/fail criteria?
Start the FAT by listing the controlled documents and their current revisions. The buyer and supplier should know which document controls if a brochure, quotation, drawing and test sheet describe a requirement differently. Put the agreed acceptance value, measurement method and responsible witness in the protocol before testing begins.
| Controlled input | What it should define | What to record at FAT |
|---|---|---|
| Purchase order and technical specification | Contract scope, material range, required functions, documentation, witness and release conditions | Document number, revision and any approved clarification |
| Approved machine drawing or data sheet | Model, arrangement, working direction, interfaces, dimensions and supplied options | Drawing revision and configuration comparison |
| Signed FAT protocol | Test sequence, acceptance criteria, material, sample method, instruments, witnesses and evidence format | Actual result, status, comments and signatures for each line item |
| Electrical, pneumatic or hydraulic documents | Delivered circuits, component identification, supply data and interface responsibilities where applicable | Revision, point checks, alarms and controlled exceptions |
| Software and parameter record, when applicable | Approved program/version, access responsibility, backups and recoverable parameter set for the delivered controls | Version or backup identity and handover owner |
| Packing and document requirements | Manuals, drawings, loose parts, tools, preservation, marks and shipping-release evidence | Completed checklist and open-item disposition |
How should machine identity and ordered scope be verified?
The witness should be able to connect every result to one physical machine. Record the machine identification and compare the visible and documented configuration with the order. A correct test on the wrong model, option set or control revision is not useful acceptance evidence.
Photograph the identification plate and the machine from consistent viewpoints. If an ordered interface cannot be tested because mating equipment is unavailable, mark that limitation in the protocol and define the later site-verification responsibility.
What belongs in the visual, mechanical and roller-system inspection?
Inspect the machine before powered testing so damage, contamination, missing parts or assembly problems are not hidden by later operation. Use the approved drawing, parts list and inspection method for the actual machine.
| Inspection area | Check | Evidence |
|---|---|---|
| Frame and assembly | Visible condition, fasteners, covers, guards, access panels, labels and agreed finish | Checklist status, photographs and deviation reference |
| Working and support rolls | Correct arrangement, clean contact surfaces, visible damage, rotation condition and approved adjustment range | Roll identification, observation and specified measurement record |
| Guides and material path | Entry/exit guides, supports and clearances match the approved configuration and intended material path | Configuration photograph and drawing comparison |
| Adjustment mechanism | Handles, indicators, actuators or stored settings move and report position as designed | Functional observation and reference-position record |
| Drive and transmission | Installed components, guards, lubrication state and visible connection condition | Component check and no-load observation |
| Utilities and controls | Nameplate/circuit match, wiring identification, bonding and service connections within the FAT scope | Qualified inspection record and controlled document revision |
What should be completed before and during no-load operation?
Before energizing, close the approved pre-start inspection: remove transport restraints as instructed, confirm the required lubrication and utility state, clear tools and people from hazard zones, restore required guards, and place connected equipment in the controlled test condition. Qualified personnel should verify the supply and protective measures against the delivered documentation.
Build the no-load test around observable functions
The protocol should state the required operating sequence and duration for the actual machine. Do not convert an old article’s run time, temperature or noise figure into a universal FAT rule.
When is a representative-material leveling test necessary?
Use a material test when the purchase specification or signed FAT plan requires proof with strip or sheet. Agree the material source and condition before the FAT: grade or strength information when known, thickness, width, initial shape, surface condition, sample length and feeding direction. A result is difficult to interpret if the incoming material is not identified.
| Record group | Minimum traceable information | Acceptance source |
|---|---|---|
| Input material | Material identification, thickness, width, incoming condition, sample orientation and photographs | Purchase specification or signed test plan |
| Machine setup | Machine identification, roll/adjustment references, speed or mode, passes if applicable and operator | Approved FAT method and machine instructions |
| Output sample | Sample identity, measurement locations, surface observation and retained-sample responsibility | Approved drawing/specification and agreed sample plan |
| Result | Actual measured values, method, instrument identity, status and comments—not only “pass” | Acceptance criteria listed in the controlled protocol |
How should flatness, surface and measurement evidence be recorded?
Write the measurement method before looking at the result. Define the datum or support condition, sample location and orientation, reference length or area, instrument type, instrument identification and calibration status, repeat method, units and acceptance rule. The record should distinguish the incoming material condition from the leveled output.
A photograph of a sample on a table is useful context but is not a flatness measurement by itself. Likewise, a machine photo cannot prove roller parallelism or output quality. Keep the visual evidence connected to the measurement record it actually supports.
Which controls, alarms and protective functions should be demonstrated?
Test the functions listed in the approved control and safety documentation for the delivered configuration. Record the test condition, commanded action, expected state, observed state and reset method. Factory simulation may be necessary for interfaces that require other line equipment, but the simulation method and remaining site test must be explicit.
Can a buyer witness the FAT remotely?
Remote witnessing can work when it is agreed in the contract or FAT plan and the evidence package is designed in advance. Send the controlled protocol and machine identity before the session, then use a live agenda that lets the witness connect each demonstration to a line item.
Remote video should supplement, not replace, the agreed measurement records and signatures. If the witness cannot see or verify a required condition remotely, keep it open or use the contract’s approved alternative rather than marking it passed by assumption.
How should punch-list items, retests and concessions be closed?
Every failed, incomplete or unverified line item needs a traceable disposition. Record the requirement, actual condition, effect, responsible party, target date and required evidence. After correction, repeat the affected test and any agreed dependent checks.
| Status | Required control | Shipment implication |
|---|---|---|
| Corrected and retested | Link corrective action and dated retest evidence to the original item | Release only after the authorized reviewer accepts the closure |
| Open before shipment | Assign owner, deadline and objective closure evidence | Do not treat a verbal promise as a pass |
| Accepted concession | Document the deviation, effect, limits and authorized written acceptance | Release only within the signed concession conditions |
| Deferred site test | State why the factory could not test it, the site method, prerequisites and responsibility | Keep it distinct from factory-passed items |
The final protocol should make the release decision unambiguous: accepted, accepted with listed written conditions, or not released. Preserve the signed record and attachments with the machine document package.
What documents and packing evidence belong before shipment release?
FAT closure and shipping preparation should meet at one release gate. Confirm that the tested machine identity matches the packing list and that corrections completed after the witness test are included in the final record.
What should a buyer send when requesting a FAT plan?
Send the project data early enough to build the protocol before manufacture is complete. At minimum, provide the material and output requirements, machine configuration, controlled drawings/specification, required functions and interfaces, representative test material plan, measurement method, witness format, documentation list and shipment-release authority.
These inputs let the supplier return a project-specific protocol instead of copying generic limits that may not match the machine, material or contract.
Frequently asked questions about leveling machine FAT
What is the difference between a factory audit and a machine FAT?
A factory audit evaluates the supplier’s identity, engineering, workshop and quality-system capability, usually before ordering. A FAT evaluates the completed machine and its evidence against the approved project requirements before shipment. See the separate factory-audit checklist.
Is there one universal flatness tolerance for every leveling machine FAT?
No. The acceptance value and measurement method must come from the purchase specification, approved drawing, signed FAT protocol or another contractually identified source for the project.
Must the FAT use the buyer’s production material?
Use the material agreed in the purchase specification or FAT plan. If substitute material is accepted, record what it represents, its limitations and whether a later test with production material remains open.
Can the FAT be witnessed by video?
Yes, when remote witnessing is agreed and the protocol defines machine identification, live views, readings, files, signatures and unresolved items. Video does not replace required measurement records.
What happens when a FAT item does not pass?
Record the requirement and actual condition, assign corrective action, repeat the affected test, and link the closure evidence. Any concession or deferred site test needs written authorization and defined limits.
What proves that the leveling machine is ready for shipment?
The agreed release authority should sign the completed FAT status after required safety and release-blocking items are closed, any remaining non-safety items are formally controlled, and the document, loose-part, preservation and packing checks are complete.
Define the FAT requirements during machine quotation
Share the machine configuration, material data, output requirement, measurement method, witness plan and release conditions during quotation so the project-specific FAT scope and required evidence can be reviewed.
