Factory Acceptance Testing: A Critical Step to De-Risk Control System Deployments

Why Factory Acceptance Testing Matters in Control System Projects

In the high-stakes world of industrial automation, Factory Acceptance Testing (FAT) is more than a formality, it's a critical milestone that validates system performance before it ever reaches the field. For control systems and OT solutions, FAT offers a structured and repeatable environment to detect logic errors, integration issues, and design gaps well before they can disrupt production.

Champion’s Edge: Infrastructure and Expertise That De-Risk FAT

We don’t just conduct FAT—we engineer it for success. Our in-house simulation environments, complete with vendor-specific control hardware, test racks, and pre-configured operator workstations, allow us to replicate real-world conditions and rigorously test every element of the system. Whether it’s Honeywell Experion®, Rockwell Automation, or Emerson DeltaV, we bring the tools and knowledge to simulate, validate, and streamline FAT execution.

By combining simulation capabilities with a deep understanding of OT applications, we ensure that your system behaves exactly as intended, under load, under pressure, and under control.

Top 5 Reasons FAT Reduces Project Risk

1. Catch Issues Before They Reach the Field

Our controlled test environments uncover misconfigurations, logic errors, and network issues long before on-site commissioning, saving time, cost, and operational downtime.

2. Validate Functional Design and Logic

From PLC code and HMI graphics to alarm management and SCADA point validation, Champion helps clients confirm that their system meets all functional specifications before deployment.

3. Boost Operator Confidence Through Simulation

Our FAT process includes realistic operator interaction using actual graphics, navigation workflows, and input/output simulations, helping users gain familiarity and confidence before go-live.

4. Strengthen Cybersecurity and Network Assurance

FAT also enables testing of industrial network solutions, Windows domain configurations, and role-based access controls to ensure secure, reliable system performance.

5. Support a Low-Risk, Structured Commissioning Phase

With Champion’s FAT preparation and documentation, commissioning becomes a controlled process, not a troubleshooting exercise.

Best Practices for Effective FAT Execution 

• Start Early: Include FAT planning in the upfront project scope and schedule.
• Test What Matters: Simulate realistic operating scenarios to validate control and safety.
• Involve the Right People: Invite operations, cybersecurity, and IT stakeholders into the FAT process.
• Document and Sign Off: Maintain detailed FAT protocols, test results, and issue tracking for project transparency.
• Close the Loop: Use FAT insights to refine configuration and installation plans.

The Champion Difference: More Than a Checklist

FAT is a safeguard—but done right, it’s also a springboard. Champion’s investment in simulation infrastructure, hardware assets, and OT domain knowledge means we don’t just test systems, we prove them, improve them, and ensure they’re ready to perform on day one.