Economical Engineering Services Australia Pty Ltd EESA Quality

FAT - Procedure
Organization: EESA QMS – ISO 9001 2015 Issue Date:
Project Number: Revision: 0.1
Document No: Sheet: 1 of 11

Table of Contents
1. Purpose...................................................................................................................................................... 3
2. Scope........................................................................................................................................................... 3
3. Users........................................................................................................................................................... 3
4. Reference Documents........................................................................................................................... 3
5. Definitions................................................................................................................................................ 3
6. FAT Procedure – Flowchart................................................................................................................ 4
7. FAT - Procedure Activities.................................................................................................................. 5
7.1 Contractual Phase.......................................................................................................................................5
7.2 Pre-Conditions and Inputs for FAT.....................................................................................................5
7.3 Plan for FAT...................................................................................................................................................6
7.4 FAT Readiness check – Virtual and In Person Sessions.............................................................6
7.5 FAT Readiness check – In person Verification...............................................................................7
7.6 Safety Management....................................................................................................................................7
7.7 Test Person Competence.........................................................................................................................8
7.8 Perform FAT..................................................................................................................................................8
7.9 Faults and Retests...................................................................................................................................... 9
7.10 Perform Post FAT Tasks..........................................................................................................................9
7.11 FAT Report Compilation.......................................................................................................................10
8. Roles and Responsibilities............................................................................................................... 10
8.1 Project Manager/Engineer..................................................................................................................10
8.2 Quality Manager....................................................................................................................................... 10
9. Measurement and Reporting........................................................................................................... 10
10. Managing Records............................................................................................................................... 11
11. Validity and Document Management............................................................................................11
 FAT Procedure

Document Control

This table shows a record of significant changes to the document.

Version Date Author Description of Change

1.0 19/3/2024 Malini Yogananth Initial release

APPROVALS

This table shows the approvals on this document for circulation, use, and withdrawal.

Version Date Approver Title/Authority Approval Remarks

1.0 Alan Alagappan Director
1.1
1.2

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1. Purpose
The purpose of this document is
 To detail all the aspects of FAT as soon as the cable/cable accessories is
manufactured and is ready to be shipped to the client.
 The intent of the FAT is to ensure that the product we deliver meets or exceeds it
minimum Australian Standard and/or Customer Design specification.

2. Scope
The scope of this document is to outline the steps and procedures of EESA FAT process that
is applicable for both virtual and in person witness of a FAT.

3. Users
Project Team
QA team

4. Reference Documents
Following are the reference documents for the Sales to Project Handover:
ISO/IEC 9001:2015- Quality Management Systems- Requirements
ISO/IEC 9001 QMS [Clause 5.1.1 General]
ISO/IEC 9001 QMS [Clause 8.1 Operational Planning and Control]

5. Definitions
FAT - Factory Acceptance Testing is a process that helps to verify the manufactured and
packaged product/material (example - cable) meets its intended purpose. As the name
suggests, it is performed at the factory preferably in the QA Lab.

QA – Quality Assurance any systematic process of determining whether a product or

service meets specified requirements. QA establishes and maintains set requirements for
developing or manufacturing reliable products.

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6. FAT Procedure – Flowchart

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7. FAT - Procedure Activities

7.1 Contractual Phase

 Check and confirm with the client if their representative(s) are going to witness the FAT
in person or virtually right at the contractual phase. This helps both the client and the
supplier to plan for the FAT witness well ahead.
 Check if there is a separate portal to update the MDR documents at client.
 Check on the client MDR requirements.
 Update all the above to the QA team as soon as the project kick off is completed.

7.2 Pre-Conditions and Inputs for FAT

Document Details Purpose

Approved All the technical specifications as Details all the constructional,
Technical per the Australian and technical
Datasheet(s) International standards AS/NZS details and measurements to be
Refer Appendix A 5000.1, IEC 60332-3-22, IEC done on product (example:
60754-1 60754-2, IEC 61034.2, cable) elements.
AS/NZS 1660, AS/NZS 4507-
RH3, AS/NZS 1125, AS/NZS
3808, AS/NZS 2373 as
appropriate
Approved All the tests that would be Details the quality assurance
Inspection Test carried out in Raw Material checks to be carried out at each
Plan(s) (ITP) Phase, In Process phase, Routine process stage and at Finished
Refer Appendix B type test and Factory Acceptance cable stage
Testing as per the Technical
Datasheet and the relevant
Australian and International
standards mentioned
Approved Quality The quality plan as per the ISO Ensures that the quality reviews
Management Plan 9001 2015 standard or its and checks are planned and
(QMP) equivalent. aligned at the organizational
Refer Appendix C level.
FAT Test The procedure for every FAT test Specifies how the test is to be
Procedure as per the relevant Australian conducted, what are the
Document and International standards precondition of samples and
Refer Appendix D what type of equipment to be
used and what are the pass-fail
criterion for every test
mentioned in the Factory
Acceptance Testing section of
ITP

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7.3 Plan for FAT

 Based on the confirmation received from the Supplier and the project team plan for the
FAT and update the FAT Tracker.
 Inform client 2 weeks prior, on the FAT date and get their confirmation to witness the
same.
 Based on the client’s confirmation to witness the FAT virtually or in person, ensure that
their itinerary is planned appropriately till the completion of the FAT.
 Verify if the sample selection for the FAT is as per AS 5000.1 for LV Cable and AS 1429.1
for HV Cable.
 Send the Packing List to the client 2 days prior to the FAT highlighted with the samples
to be tested during the FAT.
 Check and confirm with the Supplier for the FAT Calendar invite responsibility.
 Send the FAT schedule invite 3 days prior to the FAT mentioning the location, date, and
time to all those involved in the FAT, especially the client (representative) who is going
to witness the FAT either virtually or in person or both.

7.4 FAT Readiness check – Virtual and In Person Sessions

 Ensure the QA/Supplier factory people involved in the FAT are available on time on the
day of the FAT.
 If virtual session, login to the online session 5 – 10 mins ahead of the FAT start time.
 Ensure if the Network is appropriate 30 mins ahead of the FAT start time.
 During the FAT session remember to pause and speak and check with the client every
now and then if he is ok with what is happening.
 Ensure the tab(s)/mobile(s)/camera/video recorders to record the FAT are in working
condition and has proper stand to avoid shaking of the recording of the FAT.

 Ensure focus is on the test that is being done only with the test equipment, sample
tested and the stationery items to note down the actual readings.
 Ensure photographs are taken in a professional manner.

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 Ensure video recording is clear and easily accessible and downloadable to all the FAT
recipients.
 If there are issues in any of the above, then ensure to update the QA team/client on the
delayed start of FAT/ rescheduled FAT.

7.5 FAT Readiness check – In person Verification

 Ensure the QA/Supplier factory people involved in the FAT are available on time on the
day of the FAT.
 Reach the FAT venue 30 minutes ahead of the FAT start time.
 Ensure to introduce the client representative to the Supplier before starting the FAT.
 Ensure to mention the tests that are going to be performed and detail every test
performed to the client representative and get his concurrence.

7.6 Safety Management

 Ensure Attendance in the test area is only allowed with the agreement of the test
department staff. All visitors shall wear Personal Protective Equipment (PPE) such as
helmet, gloves, earplugs etc. provided [if required], and shall strictly always follow all
test personnel instructions.

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 Visual checks of the test object are only allowed in the presence of factory authorized
personnel during the tests. The authorized factory personnel shall give safety
instructions to all visitors during the visual checks.
 The emergency buttons in the test bay, may only be pushed in the event of an
emergency, as the complete power supply of the test bay will be shut down.
 Switching operations on any item of test equipment or control units in the test bay by
visitors is forbidden, except for activating the emergency stop button in the event of
emergency.

7.7 Test Person Competence

 All tests performed at the nominated test facility will be carried out by competent
personnel only.
 For complex test activities, a test assistant will be available to assist the Test Engineer.
On request, qualification and experience of the Test Engineer can be presented at the
test facility.

7.8 Perform FAT

 Introduce self and the whole QA team who will be performing all the tests to all those
who are witnessing the FAT.
 Show the sample drums (drum number) identified by the client from the packing list
and how the final packing will be done before it is sent to air/sea freight.
 Explain how much of cable will be cut from the sample drums and for what purposes.
 For every test performed show the equipment(s) used for the test along with the
calibration labels (Refer below the conductor resistance tester set displayed with the
calibration label).

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 Start every test by explaining the test procedure and showing the required value as per
the approved datasheet/Australian standard expectation and the actual value as soon as
the test is completed. (Refer the below figure which shows the Shrinkage test. Initial
length 200 mm, after shrinkage 197 mm and the expected % of shrinkage reference as
per the standard)

 Mention if the actual value has met the required value and whether the test is a pass.
 Complete all the tests as per the FAT section in the ITP.
 Close the call formally by thanking all the participants and checking if they are satisfied
with the whole FAT.

7.9 Faults and Retests

 In instances that the test does not meet the pass criteria requirement, it will be
assessed, categorized, and tagged as a fault or defect which will be rectified.
 The re-test of the equipment will be conducted upon assessment and rectification of
defects as required. The re-test will be carried out with the same pre-conditions per the
AS standards.
 The test results of the retests shall be recorded with appropriate explanation.

7.10 Perform Post FAT Tasks

 Send a thank you mail to the supplier for organizing and conducting the FAT.

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 Record the observations and list the FAT document requirements in the thank you mail.
 Follow up with the Supplier to collect the FAT documents.

7.11 FAT Report Compilation

 Compile the FAT report as per the standard format of EESA and send it to project team
for final verification with the below set of documents.
o Packing List – Highlight the drums that were sampled for the FAT.
o FAT Report – With the actual values of all the tests performed and the pass
status
o In Process/Routine/Type Test Report as appropriate
o Raw Material Test Certificates
o Calibration Certificates
o FAT Photographs
 If changes are suggested, make changes, and send it to the project team and get
acknowledgement of acceptance.
 If the client has asked to upload the same in his portal/app then ensure the same is done
and acknowledgement is received from client.
 If the video recording must be shared, then provide share access of the video to the
recipients.

8. Roles and Responsibilities

8.1 Project Manager/Engineer

Project Manager/Engineer is responsible for the implementation and accountable for this
procedure with respect to following responsibilities:

8.2 Quality Manager

Quality Manager is responsible for the implementation and accountable for this procedure
with respect to the following responsibilities:

9. Measurement and Reporting

FAT Procedure includes the following measurement and reporting activities.
 Total no. of FAT’s conducted vs No. of FAT’s participated (both virtual and in person)
 Time Taken to complete the FAT Report from the day the FAT is completed.
 Number of process improvements in the FAT procedure.

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10. Managing Records

Managing Records

Storage Person Controls for Records Retention

Record Name
Location Responsible Protection Time

Quality System Admin /

FAT Tracker One Drive NA
Manager QA Department

Quality System Admin /

FAT Report One Drive 5 years
Manager QA Department

FAT – Do’s and System Admin /

Quality
Don’ts One Drive NA
Manager QA Department
Guidelines

11. Validity and Document Management

This document is valid as of [Date]
The owner of this document is Malini Yogananth, who must check and, if necessary, update
the record at least once a year.

Document No: Sheet: 11 of 11

Revision No: Issue Date: xx-xxx-xx