Cartoning machine FAT, SAT and commissioning
Acceptance testing is strongest when the samples, operating conditions, pass criteria, deviations and responsibilities are agreed before the machine is presented for test.
Separate FAT, SAT and production handover
A factory acceptance test demonstrates the agreed machine functions at the supplier or test location before delivery. A site acceptance test confirms the installed system and agreed interfaces in the customer environment. Commissioning prepares the machine, line and people for the approved operating condition. These stages are related but should not be treated as interchangeable.
| Stage | Main purpose | Typical evidence |
|---|---|---|
| FAT | Demonstrate the machine build, approved formats, controls, inspections, faults, changeovers and documentation before shipment. | Signed test schedule, sample register, result sheets, deviation log, photographs or video where agreed, software backup and open-action list. |
| Installation verification | Confirm positioning, services, guarding, interfaces and documentation against the approved installation scope. | Connection checks, inspection records, drawings, identification, isolation and completion of site responsibilities. |
| SAT | Demonstrate the installed cartoner with agreed upstream, downstream, utilities and site operating conditions. | Interface tests, agreed production materials, challenge faults, output and quality results, deviation and retest records. |
| Commissioning and training | Establish approved settings, routines, operator competence, maintenance tasks, escalation and controlled production handover. | Recipe and format records, training attendance, first-off standard, maintenance plan, spare-parts handover and production sign-off. |
Control the materials used for acceptance
Every test result should identify the bottle, closure, label, carton blank, leaflet and other component revision used. Mark engineering substitutes and provisional samples clearly. If the final production item is unavailable, record which acceptance points remain conditional and how they will be closed later.
- Use filled-weight or safely representative products where weight and centre of gravity affect handling.
- Include the intended printed, coated and glued carton rather than relying only on plain board.
- Test the approved format combinations, not isolated components that will never run together.
- Include accepted worst-case variation where evidence exists.
- Protect test quantities from damage and preserve traceability through setup, testing and retained samples.
The carton blank design guide explains which carton attributes should remain controlled.
Write measurable acceptance criteria
A criterion should state what will be observed, the test condition, the accepted result and the evidence recorded. Avoid statements such as “runs well”, “easy changeover” or “all sensors working”. Define the format, feed condition, test sequence, accepted carton quality, permitted interventions, inspection challenges and treatment of rejects and stops.
| Category | Items to define before testing |
|---|---|
| Carton handling | Magazine loading, single-blank separation, erection, transfer, controlled stop and restart, and response to a deliberately unsuitable blank. |
| Product handling | Infeed condition, count or collation, orientation, permitted contact, incomplete group response and recovery after product disturbance. |
| Loading and closure | Product-to-carton clearance, loading result, tuck or glue sequence, finished-pack appearance and defined closure checks. |
| Leaflet, coding and inspection | Required component and code checks, challenge samples, tracking, rejection, reject confirmation and failure of the reject path. |
| Line controls | Ready, run, starved, blocked, fault, emergency-stop, upstream/downstream restart and product-clearance behaviour. |
| Changeover | Starting condition, number of people, parts and tools, settings, line clearance, first-off approval and accepted finish condition. |
| Documentation and handover | Manuals, drawings, software backup, parts lists, maintenance tasks, training, certificates where applicable and open actions. |
Manage deviations, retests and open actions
Record each departure from the acceptance plan when it occurs. The record should identify the affected requirement, material, observed result, temporary disposition, corrective action, owner, due date and retest evidence. Separate a documented concession from unfinished work and do not allow a successful result on another format to close an unrelated fault.
At site, distinguish machine defects from site-service, upstream-feed, downstream-capacity or uncontrolled-material issues. The responsibility matrix and evidence should make the boundary clear without leaving the customer to resolve an unowned interface.
Make training and handover part of acceptance
Training should cover normal running, replenishment, approved changeovers, line clearance, first-off checks, fault interpretation, safe recovery, cleaning boundaries, routine inspections and escalation. Maintenance personnel need the tasks, parts, tools and safe isolation information relevant to their role. Retain training records and confirm that the final manuals and software backups match the delivered machine.
Use the installation guide to prepare the site, the inspection guide to build challenge tests and the safety guide to allocate competent review.
Share the test plan before the machine is presented
Send the format matrix, sample status, required inspections, line interfaces and handover expectation. Lancing can then identify what should be demonstrated at factory and site.
Agree acceptance evidence before the machine build is complete
Send the approved formats, material status, required checks, site interfaces and production handover objectives.