Inverted sensors, unstable analog references, misaligned drives and unreachable devices.
FAT / SAT / Start-up / Teleservice
Industrial testing and start-up without losing control.
D&D supports testing, commissioning, first production runs and post-start-up support with tracked tests, technical priorities and clear responsibilities for maintenance, production and the machine builder.
I/O checks
FAT / SAT
Open-points list
Remote support
Where start-up gets stuck
In the field, the biggest cost comes from unfinished details.
Start-up becomes fragile when a signal, sequence, safety function or responsibility is only clarified in front of a stopped machine. The method is there to reduce that risk before the critical date.
Manual, automatic, reset, restarts and safety must be tested by scenario before production pressure.
If every issue stays in chat or spoken word, it gets hard to decide priority, owner and closure moment.
Production and maintenance must understand states, alarms, resets and limits before the plant runs at full rate.
Before the critical date
Field work runs smoothly when the scope is already in order.
Before the SAT we gather the state of the panel, software, I/O, networks, documentation and production constraints. The goal is not to start from scratch in front of the line, but to arrive with tests, roles and priorities.
Signals, sequences and critical functions are anticipated where possible.
Field, safety, line timing and operator availability all enter the plan.
Technical support, backups and operating notes stay available after the first switch-on.
Operational start-up plan
Three moments, one technical log.
The method separates what has to be checked first, what has to be decided in the field and what remains to be monitored in the first production days.
Before the FAT / SAT
Document collection, software version checks, panel status, I/O list, networks and safety constraints.
During start-up
I/O checks, functional tests, stop/restart scenarios, alarms, recipes and notes in the open-points list.
After first production
Training, backups, remote support, remaining priorities and assistance on anomalies that appear under full load.
Open-points list
Every anomaly must have an impact, an action and an owner.
An open point isn't just a problem: it's a decision to make. That is why we distinguish blocking issues, optimisations, customer tasks and checks to repeat.
Point
Axis 2 drive not ready in automatic
Impact
Cycle blocked on restart
Action
Check the enable sequence and feedback
Status
To retest with material
Field rhythm
Start-up isn't just being on site. It's controlled progress.
From FAT/SAT to first production, D&D organises tests, anomalies and technical steps with a clear method: less improvisation, more operational control.
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01 In preparation
Preparation
Software versions, schematics, I/O, networks, safety and machine constraints are verified before arriving on site.
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02 Under test
Field tests
Signals, scenarios, enables, stops, restarts and interlocks are tested methodically, not by trial and error.
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03 Closing out
Stabilisation
Anomalies are tracked, ranked by priority and closed until the line reaches controlled production.
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04 Operational
Support
Backups, technical notes, remote assistance and handover mean the customer isn't left alone after go-live.
Concrete outputs
What the customer receives at the end of the intervention.
The goal is to leave the plant governable even after the on-site presence: the tests carried out, changes, backups, open points and next actions must all be clear.
Test plan
The sequence of checks carried out or to complete, with shared priorities.
I/O report
Critical signals tested, anomalies found and corrections made.
Open-points list
Issues, impact, owner, status and next check.
Backups and versions
The software state delivered, change notes and technical references.
Operator training
Support for operators and maintenance on states, alarms, resets and restarts.
Post-start-up support
On-site or remote assistance to stabilise the plant through the first production runs.
When to call us
It makes sense to involve us before the production date is already critical.
- You have a limited downtime window and want to arrive with a ready checklist.
- The machine builder, end customer and maintenance need to close technical decisions.
- You want support for start-up, diagnostics, training or teleservice after delivery.
- There are software or panel changes to validate before increasing the production rate.
Technical contact
Have a start-up date or a downtime window?
The first step is to share the state of the project, panel, software, available time and line constraints. From there we define what to test first, what is needed in the field and which support to keep after go-live.