Automatic Welding Machine FAT Checklist: What Buyers Should Test Before Shipment

For any buyer importing an automatic welding machine, the moment before shipment is the single most important checkpoint in the entire purchase. Once the equipment leaves the factory, fixing a defect becomes exponentially more expensive - involving international freight, customs, downtime, and lost production. A properly executed Factory Acceptance Test (FAT) is the buyer's last, best opportunity to catch problems while they're still cheap and easy to fix.

Yet many buyers either skip FAT entirely or rely on a generic checklist that wasn't built for welding equipment. This guide gives you a complete, welding-specific FAT checklist so you know exactly what to test - and what questions to ask your supplier - before you approve shipment.

 

 

A Factory Acceptance Test is a structured verification process, conducted at the manufacturer's facility, to confirm that a machine meets the agreed specifications, functions correctly, and is safe to operate before it's packed and shipped. For automatic welding machines specifically, FAT goes beyond a simple power-on test - it needs to verify weld quality, motion accuracy, electrical safety, and control system performance under realistic operating conditions.

FAT is typically witnessed by the buyer, a representative, or an independent third-party inspector, either in person or via live video call.

 

 

If you're sourcing equipment internationally, the stakes of skipping FAT are higher than they might seem:

• Defects found after installation cost far more to fix - often estimated at up to 10 times the cost of catching the same issue at the factory, once you add freight, customs, and downtime.
• Remote troubleshooting is slow - a wiring issue or software bug that would take 20 minutes to fix at the factory can take weeks to resolve once the machine is on a container ship.
• Disputes become harder to resolve - without a signed FAT report, it's much harder to hold the supplier accountable for defects discovered after shipment.

A documented FAT isn't just a quality gate - it's your leverage point as a buyer.

 

 

1. Documentation & Specification Review

Before any physical testing begins, confirm the paperwork matches what you ordered:

 Purchase order specifications match the machine as-built
 Technical drawings and electrical schematics are available and current
 Bill of materials matches installed components (motors, welding power source, sensors, robot arm/gantry brand and model)
 Calibration certificates for sensors, positioners, and measuring instruments
 Material certificates for structural frame and pressure-bearing parts, if applicable
 Software/PLC/HMI version information
 

2. Visual & Mechanical Inspection
 Overall build quality, paint finish, and structural integrity
 No physical damage, misalignment, or loose fasteners
 Welding torch, wire feeder, and positioner are correctly installed and aligned
 Cable routing and cable management are secure and won't interfere with motion
 Safety guards, enclosures, and warning labels are properly installed
 Nameplates and labeling match the specified model and serial number
 

3. Electrical & Safety System Check
 Grounding and wiring connections are secure and correctly rated
 Emergency stop buttons function correctly and immediately halt all motion
 Safety interlocks (light curtains, door switches, safety fencing) trigger correctly
 Circuit breakers, fuses, and protective relays are tested
 Voltage and frequency settings match your local power supply (critical for international buyers - confirm 220V/380V, 50Hz/60Hz compatibility before shipment)
 

4. Functional / Dry-Run Test
 Machine powers on and initializes without fault codes
 All axes move through full range of motion smoothly, without vibration or unusual noise
 Positioning accuracy and repeatability meet specification
 Robot/gantry program runs a complete cycle without collision or error
 Wire feed system feeds consistently without birdnesting or tangling
 Cooling system (water or air) operates correctly during extended operation
 

5. Weld Quality Test

This is the most important - and most often skipped - stage for welding equipment specifically:

 Run a sample weld on your actual material and thickness, not just a generic test coupon
 Verify weld current, voltage, and wire feed speed settings are stable and match the welding procedure specification
 Inspect weld bead for uniform width, consistent penetration, and freedom from defects such as porosity, undercut, or lack of fusion
 Check seam tracking and repeatability across multiple sample parts
 If required by your application,- visual, ultrasonic, or radiographic - on sample welds
 Confirm duty cycle performance: run a continuous production simulation to check for overheating or performance drop-off
 

6. Performance & Load Test
 Run the machine at target cycle time to confirm it meets your required production throughput
 Test under maximum rated load or workpiece size
 Confirm accuracy is maintained after extended continuous operation, not just at startup
 Test changeover between different product types or fixtures, if your process requires it

7. Software, PLC & HMI Verification
 HMI interface displays accurate real-time parameters (current, voltage, speed, alarms)
 Recipe/program storage and recall function correctly
 Alarm and fault logging system works and is understandable
 Remote monitoring or data export features (if included) function as specified
 Language settings and user interface match what was agreed for your operators
 

8. Documentation & Packaging for Shipment
 Signed FAT report with test results, photos, and any corrective actions documented
 Operation and maintenance manual included
 Spare parts list matches the agreed contract
 Packing method is appropriate for ocean/air freight and protects sensitive components (control cabinet, sensors, torch)
 Moisture-proofing and shock indicators included for sensitive electronics, if applicable

 

 

• Travel to the factory in person - the most thorough option, ideal for large or high-value equipment orders.
• Hire an independent third-party inspector - a cost-effective way to get objective, professional verification without traveling.
• Request a live video FAT - increasingly common and accepted by most reputable manufacturers, allowing you to watch real-time testing and ask questions remotely.

Whichever option you choose, make sure the FAT results are documented in a signed report before you approve shipment - this becomes your reference point for any post-delivery disputes.

 

 

 

Buyers who conduct thorough FAT testing frequently catch issues such as:

• Inconsistent weld penetration caused by unstable current output
• Misaligned positioners causing seam tracking errors
• Software language or unit settings (metric vs. imperial) not matching the buyer's requirements
• Voltage/frequency mismatches for the destination country's power grid
• Missing or incomplete documentation needed for customs clearance or local compliance

Every one of these is far easier - and cheaper - to fix at the factory than after the machine has shipped.

 

 

 

1.What is the difference between FAT and SAT?
FAT (Factory Acceptance Test) is performed at the manufacturer's facility before shipment. SAT (Site Acceptance Test) is performed after installation at the buyer's facility, confirming the machine performs correctly under actual production conditions.

 

2.Can FAT be done remotely?
Yes. Most manufacturers now support live video FAT, allowing buyers to observe testing in real time without traveling to the factory.

 

3.Who pays for a third-party FAT inspection?
This is typically negotiated between buyer and supplier and should be clarified in the purchase contract before production begins.

 

4.What happens if a defect is found during FAT?
The manufacturer is responsible for corrective action and retesting until the equipment meets the agreed acceptance criteria - shipment should not proceed until all parties sign off.
 

 

An automatic welding machine represents a significant investment, and the FAT stage is your best opportunity to confirm that investment is protected before the equipment ever leaves the factory. A checklist built specifically for welding equipment - covering weld quality, safety systems, and performance under real production conditions - gives you far more confidence than a generic industrial equipment checklist ever could.

If you're placing an order with us, we're happy to schedule a live or on-site FAT and walk you through every item on this checklist before your machine ships - just let our team know when you're ready to arrange it.