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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 far more than a formality, it's a critical milestone that validates system functionality before it ever reaches the field.

For control systems and OT solutions, FAT provides a structured, repeatable environment to detect logic errors, integration issues, and design gaps, well before they can disrupt operations.

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

At Champion, we don’t just conduct FAT, we engineer it for success.

Our in-house simulation environments are equipped with:

  • Vendor-specific control hardware
  • Test racks and I/O simulators
  • Pre-configured operator workstations

This setup enables us to replicate real-world conditions and rigorously test each component—whether it’s Honeywell Experion®, Rockwell Automation, Emerson DeltaV, or hybrid environments.

With deep OT domain knowledge and integrated testing infrastructure, we ensure your system performs as expected—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
    Plan for FAT in your initial project scope and timeline.
  • Test What Matters
    Simulate realistic operations, not just scripted tests.

  • Involve the Right People
    Engage operations, cybersecurity, and IT stakeholders throughout the process.

  • Document and Sign Off
    Capture results, track issues, and create a clear FAT record.

  • Close the Loop
    Use insights from FAT to fine-tune configuration and commissioning.

🏅The Champion Difference: More Than a Checklist

FAT is your system’s first big test, and Champion ensures it’s a real one.

Our investment in simulation hardware, OT software environments, and seasoned engineering teams means we don’t just verify your system, we optimize it, harden it, and prepare it for day-one success

Let's collaborate.

Schedule a no-cost consultation today.



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Disaster Recovery for OT

In the world of operational technology (OT), a resilient disaster recovery (DR) plan is essential. OT environments are unique, relying on both physical and digital infrastructure, real-time operations, and specialized equipment. A disaster– whether caused by natural events, equipment failures, or cyberattacks– can severely impact these systems, leading to safety risks, production downtime and financial losses.

Unplanned downtime costs industrial manufacturers over $250 million annually.

More Than Just a Plan

A well-planned DR plan can mitigate the impact of disruptions, protect critical assets, and ensure business continuity in the wake of a catastrophic event. However, simply having a plan on paper is not enough. To ensure your DR plan’s effectiveness, it must be tested, regularly maintained, and integrated into your organization's overall risk management strategy.

76% of organizations lack a documented and validated Disaster Recovery plan.

Test and Validate

Regular reviews ensure the DR plan is comprehensive, accurate, and in alignment with the organization’s operations and technology. Further, it can illuminate potential gaps or areas for improvement. Methods include:

  • Tabletop exercises: Simulated disaster scenarios to test the plan's effectiveness.
  • Full-scale drills: Real-world tests involving actual equipment and personnel.

Verify

Verification is the process of testing the backup and recovery systems to ensure functionality is as intended. Elements include:

  • Backup verification: Routine testing of backup processes and files to ensure a reliable recovery path.
  • Recovery testing: Periodic testing of recovery procedures to ensure systems can be restored quickly and effectively.
  • Failover testing: Validate the ability of systems to switch to backup resources in the event of a failure.

Provide Training

Ensure that all relevant personnel, from front-line OT operators to IT staff, are thoroughly trained on their roles and responsibilities in the event of a disaster. This includes understanding the DR plan, knowing how to activate it, and being familiar with the procedures for recovering critical systems and functions.

The Takeaway

A robust Disaster Recovery strategy is not a luxury but a necessity. Remember: it’s not if, but when.

From maintaining safe operations to safeguarding your organization’s reputation to mitigating overall impact, the testing and verification of DR plans is essential to ensure your organization is prepared for challenges that will arise. 

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Why OT Cybersecurity Can’t Wait

The industrial landscape is evolving. The industrial internet of things (IIoT), artificial intelligence (AI), and advanced data analytics are unlocking new levels of efficiency and productivity. They’re also introducing a new, complex set of challenges for operational technology (OT) cybersecurity. Cyberattacks are becoming more sophisticated, targeting everything from power grids to water treatment facilities.
It's no longer a question of “if” but “when.” Let’s look at some common hurdles to prioritizing OT cybersecurity and explore how a partnership with Champion can help.

Challenges

"Implementing new security measures will disrupt operations or lead to excessive downtime."

By working collaboratively with your team to understand your processes and needs, we will develop a phased approach that integrates seamlessly and minimizes disruption. Ongoing support from our team will bring continuity from implementation to maintenance, ensuring smooth operation.

"Our legacy systems aren’t compatible with modern security tech."

We understand the challenges of securing legacy systems. Our team employs a layered security approach– including network segmentation and access control– to strategically mitigate risk.

"We don’t have the time or resources to design, implement or maintain new cybersecurity measures."

The global cybersecurity talent gap makes building and keeping a top-tier in-house team a constant uphill battle. Partnering with a dedicated solution provider like Champion offers a scalable solution. From meeting compliance standards to implementing cutting-edge tech and innovative strategies, our expert team has you covered.

"Cybersecurity solutions seem expensive, and the return on investment (ROI) isn't always clear."

The cost of a successful cyber attack can be astronomical– encompassing operational disruption, financial loss, and enduring reputational damage.

Recovering a single GB of data from a ransomware attack cost an average of $53,000 in 2023.*

Our risk-based approach and tailored solutions provide measurable improvement in your security posture and maximize your ROI.

The Takeaway

Industrial organizations can no longer afford to overlook cybersecurity. With the ever-evolving threat landscape, a robust security posture is essential for protecting critical infrastructure, ensuring operational continuity, and safeguarding valuable data. Our team is here to keep your operations running safely and securely so you can focus on what you do best.

*The Global OT & IoT Threat Landscape Assessment and Analysis Report, Sectrio, 2024

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3 Ways to Mitigate Risk Through Training

Are your operators prepared in the event of an abnormal process situation? Do they know how to actively (and appropriately) respond to alarms?
Mitigate your facility’s risks by providing your operators with training opportunities that improve user confidence and decrease response time to abnormal situations, resulting in using your workforce’s time more effectively.
How, you ask? By empowering your operators by providing them hands-on experience with your specific control system in an isolated/controlled environment, simulating an array of abnormal scenarios that you can’t effectively achieve on-process – and doing so conveniently at your facility or one of Champion’s nearby locations.

Step 1: Identify Risk Areas & Practice Responding

Take a minute to imagine any or all “worst case” scenarios your facility could one day face – that if not handled properly could result in a Health & Safety event, equipment failure, or simply a loss of production. It sounds pretty ominous! But it doesn’t have to. Knowing what these situations are is the first step to mitigating risk and effectively responding – without hesitation and without panic.

Your scenarios typically don’t need to go so far as a “doomsday apocalypse” – often something as simple as a failed sensor or an unrecognized alarm could present risks with untrained personnel.

This is where Champion comes in – to create a “twin” of your control system and operating environment. In this simulated environment, we can introduce any number of scenarios, teaching first how to identify the risk and then how best to respond.

Step 2: Stop “Snoozing” That Alarm

We’ve all done it from the comfort of our bed – “snoozing” that daily alarm for “just a few more minutes.” Regularly doing the same with control system alarms may be an indication you are due for an assessment by one of Champion’s Alarm Management specialists – but that is a topic for another day!

Training your personnel how to properly identify, evaluate, and respond to alarms and responding to abnormal situations in your facility is a big part of mitigating risks. Using the same example of your control system “twin,” Champion can effectively train users based on your process environment. Each possible abnormal scenario can be triggered in a no-risk environment – with users learning in each case how to respond to an abnormal situation in a timely and correct manner.

Step 3: Work Smarter, Not Harder

Training your workforce shouldn’t be a major undertaking – it should be a well-coordinated, preplanned, and efficient use of your personnel’s time. Champion values these goals for all clients, whether providing on-site training at your facility or at one of our strategically located facilities.

  • Do you have new personnel or a new facility?
  • Is your existing facility undergoing a control system upgrade?
  • Do your technical personnel want more flexibility to perform system updates and modifications?

There are plenty of scenarios in which your workforce may benefit from Champion-tailored training solutions for operators, maintenance, and technical personnel. Whether getting everyone up to speed on a new system, comparing changes between a legacy and new system, or learning how to stay agile in the onsite maintenance & updates your site might require.

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The Top 3 Benefits of a Third-Party Cybersecurity Assessment

Most companies are not compliant with mandatory industry or governmental guidance and regulations relating to their cybersecurity practices. In fact, only 23% of companies who participated in a 2018 Kaspersky study report that they meet the standards. [1]
Even further, 56% of companies say they will increase their cybersecurity budgets in the next year due to potential incidents and risks associated with their current infrastructure and policies. [1]

One of the first investments your organization can make is to perform a Cyber Criticality Assessment. A Cyber Criticality Assessment is a process that allows organizations to identify general threats, determine the worst-case impact, whether it’s Financial, Safety, Health, Environmental, or otherwise, of devices/software becoming unavailable, unreliable, or compromised. The assessment process includes a survey, a vulnerability assessment, and a risk assessment to allow your organization to determine the severity of the consequences should a device or network not perform as intended.

There are key benefits to inviting a professionally certified, expert third-party team to perform your cybersecurity assessment.

1. Unbiased approach to your system.

Third-Party Assessment teams do not represent any hardware or software manufactures. This enables them to take an unbiased approach to your system. While internal teams may have critical knowledge of your control system and may have even designed it, third-party assessors can see both macro and micro-levels of your control system. They will see gaps in a system that internal teams can miss.

This is doubly important when it comes to Operational Technology (OT) and Industrial Control Systems (ICS) because all control system manufacturers have their own products and solutions for implementation. An unbiased third-party assessment team, especially one with a deep understanding of OT systems can connect manufacturer solutions with industry best-practices for solutions that fit your requirements.

2. Cybersecurity experts with the necessary background are difficult, if not impossible, to find.

The cybersecurity industry is expanding and growing at an astounding rate, and the demand for qualified and experienced professionals is fierce. Even when they can’t find qualified professionals to hire, many companies are still hesitant to hire outside help. According to a Kaspersky study released in 2018, 92% of companies who participated in the Kaspersky study prefer to maintain in-house OT and ICS cybersecurity personnel [1]. At the same time, 58% percent of companies find it difficult to find and hire employees with the necessary skills to address their organization’s OT/ICS cybersecurity challenges [1].

  • Is your company in a position to contribute resources to compete in the cybersecurity hiring market?
  • Is your company willing to be responsible for the cost of ongoing training, specialization, and other costs that come with hiring full-time personnel?
  • Does your company have the time and capacity to invest in a ground-up OT/ICS cybersecurity program from within?

If not, consider working with a third-party OT/ICS cybersecurity team who has the expertise and personnel to do the bulk of the work for you.

3. IT vs. OT – It’s not a competition, it’s a complementary approach.

Cooperation and collaboration between OT and Information Technology (IT) is critical for your company’s complete, comprehensive cybersecurity investment. But does your IT team have OT knowledge and expertise?

A third-party assessment team with an OT/ICS background can connect manufacturer products and solutions with industry best-practices and methodologies that meet your requirements. They fill in the OT knowledge gaps that your IT team may lack. For example, assessors with OT backgrounds can provide insight on which control hardware your system uses that meet ISASecure® standards [2]. This is especially critical if your control system uses hardware and software from many different manufacturers.

A top-rated cybersecurity team with both IT and OT backgrounds can help to ensure that your cybersecurity assessment includes all aspects of your control system and business networks while working with your already-established IT team.

If you’re interested in learning more about Cybersecurity System Assessments for your system and establishing a strong foundation for your company’s cybersecurity policies and procedures, click here to reach out to Champion’s team of cybersecurity experts.


[1] Kaspersky, “2018-Kaspersky-ICS-Whitepaper.pdf,” 2019. [Online]. Available: https://ics.kaspersky.com/media/2018-Kaspersky-ICS-Whitepaper.pdf

[2] ISA, [Online]. Available: https://www.isasecure.org/en-US/Certification

Savoy Stewart, “firms-investment-on-cyber-security-by-industry,” [Online]. Available: https://www.savoystewart.co.uk/blog/firms-investment-on-cyber-security-by-industry

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Humans: A Weak Link in Network Security

A number of studies have found that untrained employees are the biggest threat to an organization’s network security. A study[1] by ESI ThoughtLab found that 87% of executives are aware of this fact. Consequently, companies of all industries and sizes are now putting more focus on preventing (or minimizing) attacks by investing in training for employees using Operational Technology (OT) systems including Industrial Control Systems.

Common Pitfalls

  • Operators accidentally click on a link in a phishing email from an operator station
  • Poor credential management: Allowing unrestricted access to system areas or functions that are not needed for an operator’s job role
  • Incident preparedness: No incident response program. What if something did happen? Is there a well-prepared plan in place
  • User’s credentials are not removed from system when leaving the company.

Mitigation through Cybersecurity

Even trained employees are human. The good news is many weak links can be prevented by improving the security of your ICS network.

Champion’s Certified Cybersecurity Experts are trained in the latest ISA/IEC 62443 and NIST standards for Industrial Cybersecurity. This means you benefit from the most current, comprehensive safeguards for your operations.

Industrial Cybersecurity is an ongoing cycle of assessing vulnerabilities, implementing solutions, and maintaining secure operations without production downtime.

Champion can help you by providing Vulnerability & Risk Assessments of your current network, then offer System Hardening and Configuration to mitigate risks. We can also help you in developing Cybersecurity Policies and Procedures, implementing best practices, and recovery steps for incident response in the event of an attack. We can even host a complete backup of your control system to get you up and running with little or no downtime, should a major disaster strike.

Lastly, as your Cybersecurity Experts, Champion can maintain a secure live Intrusion Detection & System Recovery Systems, Investigate Incidents, and provide a comprehensive incident response plan that fits your needs.

[1] Source: https://www.controleng.com/articles/untrained-staff-is-the-biggest-cyber-risk-according-to-report/

Source: https://www.exida.com/Blog/cyberattacks-succeed-where-humans-and-systems-are-weak

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