A few weeks ago, I conducted a Factory Acceptance Test (F.A.T.) to evaluate the equipment's condition before receiving a process skid. Using tools such as a laser aligner, infrared camera, and vibration analyzer, I performed a thorough condition check. This proved to be incredibly beneficial as I discovered major misalignment issues with three pumps on the skid. One pump was found to be .280 out of alignment in the horizontal axial plane, with other measurements showing excessive and unacceptable results. Addressing these alignment issues before delivery prevented the need for costly repair work within the next 6 months. By utilizing these tools during the acceptance test, we were able to save hundreds, if not thousands, of dollars in the long run. The supplier of the skid was impressed by our proactive approach and even had several people assist during the process. This marked the first time in the company's 50+ year history of building food processing equipment that a buyer had brought in tools for validation and acceptance. It is worth noting that the pumps in question were supplied as complete Mounted drive assemblies by a company with a long-standing reputation. This experience has made the skid fabricator more aware of the quality they receive, allowing them to better control the quality they deliver. Remember, good input results in good output.
This proactive defect elimination exercise exemplifies a substantial investment in quality assurance, going beyond just superficial efforts like "kicking the tires." It's a proactive approach that avoids the pitfalls of relying on vendors and emphasizes prevention over reaction.
Were there specific tests, complete with steps and acceptance criteria, that you or your team had prepared to run during the FAT? Additionally, what other tests were conducted during the process?
It is crucial for the fabricator to thoroughly document their work results for client or third-party review. The client is only required to be present at milestone inspection points at a minimum. This documentation process ensures transparency and accountability in the fabrication process.
During our initial attempt to use various diagnostic tools such as vibration analysis, infrared thermography, and alignment checks on the skid, we found that it was not exhibiting any signs of overheating. While we did not have a predetermined checklist for each technology, we relied on our expertise and the data at hand to draw conclusions and carry out necessary repairs. The insights gained from this experience will enable us to establish new standards to incorporate into future RFQ's and RFI's. I wholeheartedly support Josh's sentiments and believe that some manufacturers already have robust QA programs in place. However, as purchasers of unique equipment, we should demand top-tier quality for our investments. Maintenance departments within the Plant are responsible for all assets not covered by maintenance agreements or service contracts, so any additional measures we can take to enhance manufacturer QA programs should be viewed as value-added initiatives.
That's an impressive case of proactive quality control! Your experience really highlights the importance of conducting thorough Factory Acceptance Tests to uncover potential issues prior to delivery. Using specialized tools during the inspection process is a great strategy that can lead to substantial savings in the long run. It's encouraging to hear that the supplier responded positively to your meticulous approach, as it shows that they value your business and understand the importance of delivering quality products. Your story underscores the fact that having a reliable reputation shouldn't exempt suppliers from thorough quality checks - an important takeaway for all industries.
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Answer: - A Factory Acceptance Test (F.A.T.) is a process used to evaluate the equipment's condition before it is received. It is important as it helps identify any issues or defects in the equipment before delivery, preventing costly repairs or downtime in the future.
Answer: - Tools such as a laser aligner, infrared camera, and vibration analyzer were used during the Factory Acceptance Test to perform a thorough condition check of the equipment.
Answer: - By utilizing tools during the acceptance test, major misalignment issues with three pumps on the skid were discovered and addressed before delivery, preventing the need for costly repair work in the future. This proactive approach saved hundreds, if not thousands, of dollars in the long run.
Answer: - The supplier of the skid was impressed by the proactive approach of using tools during the acceptance test. They even had several people assist during the process, highlighting the importance of thorough validation and acceptance procedures.
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