When investing in new automation, one question often rises to the top: should you conduct a Factory Acceptance Test (FAT)? A FAT allows equipment and systems to be tested in a controlled environment before they are installed in a live production facility. It’s designed to catch equipment incompatibility, logic errors, integration challenges, and safety concerns early—before they turn into costly downtime. For companies adopting new or complex technologies, especially robotics, a FAT can provide the confidence and continuity needed for a smooth launch.
That was exactly the case when a 70-year-old Billion-dollar food manufacturer partnered with Systems in Motion to modernize the secondary packaging and palletizing portion of its small package production area—about 50% of the downstream production line. The goal was to reduce equipment redundancy, increase automation, and improve throughput and efficiency as part of a facility expansion. The solution included a conveyor and spiral system, a fully automated robotic palletizer, a pallet dispenser, and a heavy-duty MiR AMR to transport 40×48 pallets. Together, the technologies streamlined the process from packaging to palletizing and transport, eliminating multiple manual steps and significantly reducing labor requirements.
Because both the robotic palletizer and the MiR autonomous mobile robot technology were new iterations for the client, the team agreed early on that a FAT was essential. According to Project Manager Mark Alomia, the in-depth, week-long onsite FAT allowed everyone to test the system as close to real-world conditions as possible, but outside the pressures of the live production floor. The client brought engineering staff, QA, and safety personnel to participate, and Systems in Motion provided technology suppliers and experts. This 360-degree review created an open forum to ask questions, validate safety protocols, and fine-tune system logic before installation. The result? A more intuitive, controlled robotics process and a much smaller installation window once the system moved to the plant.
From a controls perspective, the FAT proved invaluable. PLC Engineer Ben Klebs noted that integrating the palletizer, conveyor controls, and MiR fleet software required precise communication between the PLC, PC, and robot fleet management system. Handling that integration during the FAT eliminated the need for extensive troubleshooting onsite. It also helped ensure compliance with the client’s safety standards and reduced operational risk. The payoff was significant: where 10–15 operators were initially required in the area, the new automated system now operates with approximately three to four team members—and without the need for a dedicated forklift operator. Less downtime, improved productivity, and enhanced safety became tangible outcomes rather than projected benefits.
For the client, the FAT wasn’t just a technical checkpoint—it was a strategic investment. As Account Executive Gabriel Gandara explained, FAT’s can be invaluable when timelines are tight and expectations are high. In this case, it was well worth the cost to remove potential bugs early and accelerate commissioning. The system now feeds empty totes into conveyors, moves product through packaging machines to a modular palletizer, and uses MiR technology to stage and deliver empty pallets automatically. With only two SKUs flowing to a larger distribution center, the streamlined setup delivers better throughput and efficiency while supporting the client’s commitment to innovation. For companies considering advanced automation, a Factory Acceptance Test may be the step that transforms uncertainty into an A+ outcome.
