Equipment FAT Checklist Template (Free, PDF/Excel)

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11 critical items still open - these are the highest-risk gaps.

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Documents and readiness

Approved FAT procedure and acceptance criteria are agreed with the customer in writingCRITICALMachine specification and contract scope are available to the test teamElectrical drawings, pneumatic and hydraulic diagrams are released at the current revisionBill of materials matches the as-built machineTest samples, product or gauge materials are on handMeasurement equipment calibration is current and recorded

Mechanical inspection

Frame, base and levelling feet are inspected for welds, finish and dimensionsFasteners are torqued and marked per assembly instructionLubrication points are filled and labelledGuards, doors and covers fit and open without interferenceMoving axes travel the full stroke without binding or unusual noiseKey dimensions are checked against the layout drawingCRITICAL

Electrical, pneumatic and hydraulic

Insulation resistance and ground continuity are measured and recordedCRITICALMain supply voltage, phase sequence and frequency match the specificationPanel wiring, labels and terminal markings agree with drawingsAir supply pressure, leaks and regulator settings are checkedHydraulic pressure, relief setting and leak check are recordedMotor current and drive parameters are logged for each axis

Safety functions

Emergency stop circuits stop all hazardous motion and require resetCRITICALDoor interlocks and light curtains stop motion when opened or brokenCRITICALSafe stopping time or distance is measured and recordedCRITICALLockout points and stored energy release are verifiedWarning labels, safety signs and pictograms are fittedSafety function test results match the risk assessment performance levels

Controls and software

PLC, HMI and drive software versions are recorded and backed upCRITICALAll operating modes are demonstrated: manual, setup and automaticAlarm and fault messages are triggered and displayed correctlyRecipe or part number changeover is demonstratedUser levels and passwords function as specifiedCommunication to line equipment, MES or ERP is tested where in scope

Performance run-off and close-out

Cycle time is demonstrated against the contracted rateCRITICALCapability or yield run is completed on the agreed sample sizeCRITICALProduct quality checks meet drawing tolerancesPunch list of open items is written, owned and datedCRITICALSpare parts list, manuals and training plan are confirmedCrating, shipping and rigging instructions are reviewedFAT report is signed by supplier and customer representativesCRITICAL

Mark each item as passed, or leave it open. Any open critical item should block release for shipment unless the customer signs a documented waiver.

Tie FAT results to the project record

Optional review of how FAT findings and punch list items can be tracked against the project in your ERP.

Optional. The tool and every export work without this. No spam.

How to use this checklist

Treat the checklist as a starting skeleton for the FAT procedure, not a replacement for it. Before the test, agree the acceptance criteria with the customer: cycle time, yield, tolerances, safety performance and what counts as a pass. During the test, tick items as they are demonstrated and note readings beside them. Items marked critical should stop release if they fail. At close-out, convert every open item into a punch list entry with an owner and a due date, and have both parties sign the report.

Share the procedure with the customer at least a week before the test.
Record serial numbers and revisions of what is being tested.
Photograph nameplates, panels and safety labels.
Do not change software between test and shipment without a change record.

What a FAT is and is not

A FAT verifies conformance to specification under controlled conditions. It is not a substitute for the site acceptance test, where the machine runs with real product, utilities and operators, and it is not a design validation. The practical value of a FAT is cost: a defect found in your shop costs hours, while the same defect found after installation costs travel, downtime and reputation. Many contracts release a payment milestone on FAT completion, so the quality of the record matters commercially as well as technically.

Performance run-off design

Define the run-off before the test: sample size, product, duration and what is counted as a failure. For a throughput claim, run long enough to include normal micro-stops, not a best-minute burst. For a quality claim, use enough parts to support the capability index you are promising; a handful of parts cannot demonstrate a Cpk of 1.67. Record any adjustment made during the run, because the customer will want to know whether the machine holds its setting or needs operator help.

Common mistakes

Typical FAT failures are not mechanical. They are an unagreed acceptance criterion, test material that does not represent production product, documents still at the wrong revision, and safety verification left until the last day. Another common problem is accepting a long punch list without dates; items without owners tend to arrive at site as the customer's problem. Keep the punch list in a tracker and review it in your next project meeting until closed.

Frequently Asked Questions

Who should attend a FAT?

At minimum the supplier test engineer and project manager. The customer typically sends a quality or operations representative and sometimes a safety specialist. Controls and mechanical engineers should be on call. Agree attendance in the contract, since witnessed tests need travel and schedule planning.

What happens if the machine fails the FAT?

The failures are logged, root cause is found, and the failed test is repeated after correction. Contracts usually say whether a partial retest is allowed. Minor failures can be moved to a punch list with customer agreement, but critical safety or performance failures normally require a full retest.

How is a FAT different from a SAT?

A FAT happens at the supplier site before shipment, with test conditions the supplier controls. A SAT happens at the customer site after installation, with real utilities, product and operators. The SAT confirms the machine still performs after transport and in its working environment.

Do I need a separate checklist per machine?

Yes for items that depend on machine features. Keep the group structure and critical items, then add or remove lines for your equipment, such as robot calibration, vision verification or vacuum leak rates. Version the template so each project records which revision was used.

If you want FAT results, punch list items and serial-level records linked to the project in your ERP, Netray can help set that up as a controlled workflow.

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Equipment FAT Checklist Template