Sunday, April 15, 2012

Learn from FAT - Success of Disaster

With all difficulties & disabilities we have completed a FAT today!  Cheers to you all and the team.

Many thanks to Mr.Basu to drop in upon my request as the end user was really boiled up due to series of issues related to various projects.  We all could see his presence had softened the situation a bit.

However I would like to point out certain remarks which need to be followed strictly in every such occasion.
1)    Self check prior to the FAT – which we call as internal functions check.
a.    It’s not only to check but also to take corrective action if a discrepancy is noted.
b.    We had preliminary check (with all drawings and physical checks), but unfortunate that corrected drawings remained in the computer / laptop and inspector discovered a totally different set of drawings in the FAT file.
FAT File (folder) to be compiled with maximum care to avoid such instances in future.
2)    Communication between customer / consultant / contractor to be ready at the time of FAT.
a.    Mostly the FAT would be upon official approval.  Very rare instances we have been asked to follow a previous approval in case if the deliverable is an extension of previous / recent project.
b.    Always approvals / copies of reference project documentation to be available at the FAT facility.
c.    The documentation soft copies (native files – AutoCAD / Word / Excel) to be available with the FAT conductor (vendor – DESCON) at the time of FAT.
                                          i.    It was really tough time to have a native file send over internet and access from an assembly facility with limited internet access!
                                         ii.    I would recommend carrying the project laptop during such FAT / sessions even when it is not needed.
3)    As built drawings to be ready at the time of inspection.
a.    Ideal conditions (which never happens in projects) the submittal drawings and as built drawings will be matching.
b.    In case if some changes (due to improvement in design or as per comment compliance) those need to be marked in drawings and subsequent “change instructions” to be available during the FAT.
c.    Inspector (client / consultant / contractor) is expected to inspect the assembly against the approved (AS BUILT) drawings.  So vendor must be ready with all required data.
4)    Further to successful FAT a certificate along with punch points marked (if any) to be compiled upon conclusion of FAT.
a.    Without documentation, nothing is complete in any projects.
b.    Minute Of Meeting in the FAT (in case if a discussion / clarification meeting was held) to be formulated.  This can be an evidence to “dispatch release” of the inspected goods / equipment.
c.    A signature in a FAT document is a responsibility taken by the signatory.  Same applicable for punch points so as to correct the punch point and to close any open issues later on.
5)    Last point is to update the document schedule with relevant revision marks with respect to FAT.
a.    Always keep our internal document schedule updated with maximum information (reason for revisions – internal as well).
b.    Document release check list to be followed while forwarding a set of document is sent to customer.