Testing and Validation in Custom Machines: How We Establish Criteria and Prove Performance

Custom machines are tailored to your specific process and goals, so there are more variables than with standard, off-the-shelf equipment. To ensure success, KT Tech treats testing and validation as a core part of every build. We define measurable criteria with you upfront before conducting structured testing throughout the project.

Start With a Clear User Requirements Specification (URS)

Testing and validation planning begin even during the earliest project conversations. As part of a URS, we work with you to define key requirements such as:

• What the machine must do: Core functions, required outcomes

• What success looks like: Quality metrics, throughput targets, yield expectations

• How we will verify those outcomes: Test methods, pass/fail definitions

Early alignment prevents late-stage delays or surprises from different interpretations of success. Testing becomes a straightforward, structured confirmation process when everyone agrees on requirements upfront.

Using Samples to Validate Performance

Product samples are extremely valuable for proving that the machine works in conditions that match your expectations. They allow us to validate critical factors like tolerances, consistency, and more. We typically need enough sample variety to reflect normal manufacturing variation, so we can confirm the machine performs correctly.

When a project starts very early in a product’s development, customers don’t always have enough parts available for thorough testing. If samples are limited, we’ll align with you on what can and can’t be proven at that stage and run the best tests available. In most cases, we can remain flexible and continue refining the system as new parts become available.

Proving Core Functions Early to Prevent Rework

Every custom machine project is unique, and that means unexpected issues can show up everywhere, from mechanical motion to cycle timing. We prioritize proving out core function as early as possible before moving onto guarding, covers, or secondary features. This approach simplifies troubleshooting and prevents added costs from rework late in the build.

Aligning on Safety and Compliance Requirements

We will always confirm standards and requirements that may apply to your industry or site. For regulated industries like medical devices, we know there can be additional requirements around cleanliness or preventing particulate generation. As a result, we account for those from day one in our validation plans. 

Beyond industry-specific requirements, we follow recognized ISO-based machine-safety principles.

Confirming Acceptance and On-Site Verification

As the machine nears completion, we’ll be transparent about its current status and its latest milestones. Once completed, we collaborate on a Factory Acceptance Test (FAT). In an FAT, we’ll run through the agreed URS requirements and formally verify performance.

Once it passes the FAT, we deliver and install the machine. At that point, we’ll perform an on-site acceptance test to confirm it operates the same way in your facility as it did in ours. This step, like the rest of our workflow, is intended to prevent any surprises once it enters your production process.

Let Us Automate Your Bottleneck

If you have a manufacturing challenge you want to automate, we’ll help you define success criteria and validate performance before the machine goes live. Contact us or request a quote to discuss how we can help you solve your problem!