Factory Acceptance Test (FAT) for Profile Accuracy in Roll Forming

The Complete Pre-Shipment Verification Guide

A Factory Acceptance Test (FAT) is performed:

At the manufacturer’s facility
Before machine shipment

Its purpose is to verify:

• ✔ Profile geometry accuracy
• ✔ Tolerance compliance
• ✔ Speed capability
• ✔ Structural stability
• ✔ Cutting accuracy
• ✔ Punch accuracy (if applicable)

FAT protects the buyer from:

Receiving an underperforming machine.

Once the machine ships internationally, correcting errors becomes:

Expensive and time-consuming.

1️⃣ Why FAT Is Critical

Without FAT:

• ✔ Tooling errors may go unnoticed
• ✔ Motor undersizing may be hidden
• ✔ Cutting distortion may not be identified
• ✔ Springback compensation may be wrong

A proper FAT confirms:

The machine performs exactly as specified.

2️⃣ FAT Must Be Performed Using Real Production Material

Machine must be tested using:

• ✔ Correct thickness
• ✔ Maximum yield strength
• ✔ Full profile width
• ✔ Correct coating type

Testing thin mild steel instead of high-strength material hides real load issues.

Always test worst-case material.

3️⃣ Dimensional Verification Checklist

Measure and record:

• ✔ Overall width
• ✔ Effective cover width
• ✔ Rib height
• ✔ Rib pitch
• ✔ Flange dimensions
• ✔ Bend angles
• ✔ Return lips

Measurements must match approved drawing within tolerance.

Use calibrated digital measuring tools.

Document results.

4️⃣ Length Accuracy Test

Run panels at:

Multiple lengths (e.g., 2m, 4m, 6m).

Verify:

• ✔ Encoder calibration
• ✔ Cutting synchronization
• ✔ End squareness

Length drift indicates encoder or cutting issues.

5️⃣ Speed Verification

Test at:

• Low speed
• Nominal speed
• Maximum specified speed

Verify:

• ✔ Dimensional stability
• ✔ Vibration level
• ✔ Surface quality
• ✔ Motor temperature

Machine must maintain tolerance at full rated speed.

Not just at slow demonstration speed.

6️⃣ Motor & Electrical Load Test

Record:

• ✔ Motor current draw
• ✔ Voltage stability
• ✔ Overload margin

Motor should not run near overload during normal production.

Electrical stability confirms correct motor sizing.

7️⃣ Shaft & Frame Stability Check

Inspect during operation for:

• ✔ Excessive vibration
• ✔ Shaft deflection
• ✔ Roll chatter
• ✔ Bearing noise

Profile accuracy must remain stable under load.

Excessive deflection indicates structural weakness.

8️⃣ Cutting System Verification

Inspect cut edges for:

• ✔ Burr
• ✔ Rib deformation
• ✔ End flare
• ✔ Profile collapse

Blade geometry must match profile.

Check repeatability across multiple cuts.

9️⃣ Punching Verification (If Applicable)

Verify:

• ✔ Hole position accuracy
• ✔ Hole size tolerance
• ✔ Punch repeatability
• ✔ Burr control

Test multiple hole patterns.

Punch alignment errors can destroy installation accuracy.

🔟 Springback Compensation Test

For high-strength steel:

Confirm final angles match drawing after material relaxes.

Incorrect compensation leads to:

Seam mismatch
Dimensional drift

Springback must be verified with production material.

1️⃣1️⃣ Oil Canning Inspection

Visually inspect panels for:

✔ Surface waviness
✔ Distortion under natural lighting

Run full-width panels to detect structural inconsistency.

Oil canning often appears only at production speed.

1️⃣2️⃣ Fit & Overlap Test

Assemble two panels.

Verify:

• ✔ Seam engagement
• ✔ Overlap alignment
• ✔ Water channel positioning

Fit testing reveals dimensional deviation quickly.

1️⃣3️⃣ Profile Repeatability Test

Run:

Minimum 10 consecutive panels.

Measure consistency.

Tolerance drift across panels indicates:

• Setup instability
• Structural weakness
• Material control issues

Repeatability is as important as initial accuracy.

1️⃣4️⃣ Documentation Requirements

FAT report should include:

• ✔ Measured dimension table
• ✔ Material specification used
• ✔ Speed test results
• ✔ Motor load data
• ✔ Photos of panels
• ✔ Video of production run

Buyer must sign FAT report before shipment.

Documentation protects both parties.

1️⃣5️⃣ Common FAT Mistakes

• ❌ Testing only at low speed
• ❌ Using mild steel instead of high-strength
• ❌ Skipping full-length panels
• ❌ Not documenting measurements
• ❌ Ignoring vibration

A casual FAT increases post-installation risk.

1️⃣6️⃣ Export & Certification Consideration

If machine will produce:

Certified structural panels,

FAT profile must match:

Certified geometry exactly.

Any deviation invalidates test data.

FAT is part of compliance chain.

1️⃣7️⃣ What Happens If FAT Fails?

If machine does not meet tolerance:

• ✔ Tooling must be adjusted
• ✔ Shaft alignment corrected
• ✔ Cutting system modified
• ✔ Control system recalibrated

Machine should not ship until issues are corrected.

Shipping before resolution transfers risk to buyer.

1️⃣8️⃣ Engineering & Procurement Summary

A proper FAT verifies:

• ✔ Dimensional accuracy
• ✔ Structural stability
• ✔ Motor sizing adequacy
• ✔ Cutting precision
• ✔ Punch accuracy
• ✔ Speed capability

FAT ensures:

The machine you ordered
Is the machine you receive.

It is one of the most important risk-control steps in roll forming procurement.

FAQ Section

Should I attend FAT in person?

Highly recommended for major investments.

Can FAT be done remotely?

Yes, but requires detailed video and measurement documentation.

How long should FAT take?

Typically 1 full day for thorough testing.

Should testing include maximum thickness?

Yes — always test worst-case material.

What if tolerance is slightly off?

Tooling adjustment must be done before shipment.

Is FAT legally binding?

Only if included in contract.