From factory acceptance through integration into your production process to final acceptance—the entire process explained in an easy-to-understand way.
With a turnkey robot solution, you’re not just buying hardware—you’re buying a promise: In the end, a defined process will run reliably in your facility. The moment when planned technology becomes a productive reality is called commissioning. It determines whether your system delivers the required output on time—or whether it grinds to a halt for weeks.
This article explains step by step how the commissioning of a turnkey robot solution works, what phases are involved, how long they typically take, and what you should keep in mind to ensure a smooth ramp-up.
Commissioning is the structured transition of a system from the installed state to productive operation. It’s not just a matter of pressing a button and turning on the robot. It involves coordinating the interaction of all components—robots, grippers, safety systems, sensors, conveyor systems, and controls—so that the process achieves the agreed-upon performance.
With a turnkey solution, the supplier bears primary responsibility for this. They not only get the system up and running but also demonstrate that it meets the promised output, cycle times, and quality standards under real-world conditions. Your task is to create the necessary conditions on the shop floor and to verify this during acceptance testing.
Commissioning proceeds in clearly defined phases that usually build on one another. A reputable integrator works through them systematically rather than improvising directly on the production floor. The following diagram shows the typical process from factory acceptance testing to series production approval.
1. FAT Factory Acceptance Test 2. Installation On-site 3. Commissioning Optimization 4. SAT Acceptance 5. Production Approval Commissioning Process At the supplier’s facility → in your facility → binding verification → production The five phases from factory acceptance to series production approval.Commissioning does not begin in your facility, but at the supplier’s site. During factory acceptance—known in technical jargon as the Factory Acceptance Test (FAT)—the fully assembled system is tested at the integrator’s site before it is shipped to you. You or a representative from your team typically travels there for this purpose.
The reason for this: Errors can be corrected much more quickly and cost-effectively at the manufacturer’s site than later in your ongoing production. During the FAT, you verify whether the robot correctly handles your actual components, whether the cycle time is met, and whether the safety functions are working properly. Ideally, you’ll send the supplier representative samples of your original parts in advance—including the “tricky” variants.
Only once the FAT is successful is the system disassembled and shipped. Passing the FAT is an important milestone, but it’s not a guarantee: some issues only become apparent in your actual production environment.
After transport, the system is set up, aligned, and connected in your facility. This phase may seem mechanically simple, but it depends heavily on how well you’ve prepared. To ensure setup proceeds smoothly, the following requirements should be met:
Once these points are prepared, the physical setup often takes only a few days. Delays usually arise not from the robot itself, but from missing connections or an installation site that hasn’t been cleared.
Now the core of the commissioning process begins. The system runs for the first time in your real-world environment, and this is precisely where the subtle differences between lab conditions and everyday production become apparent. The integrator sets gripper forces, adjusts camera systems, calibrates positions, and fine-tunes motion sequences until the process runs stably.
Typical tasks in this phase include fine-tuning the cycle time, adapting to the tolerances of your actual components, and handling special cases. Experience shows that it is precisely these special cases—dirty parts, slight dimensional deviations, unusual lighting conditions—that require the most effort. The following chart shows a rough breakdown of how time is allocated during the ramp-up phase.
Where the time goes during the run-in phase Special Cases & Outliers 40% Calibration & Image Processing 25% Cycle time fine-tuning 20% Interfaces & Data Connectivity 10% Other 5% Guidelines—the actual distribution depends heavily on the process and the variety of components. The greatest effort is rarely required during standard operations, but rather when dealing with exceptions.This phase is iterative: test, measure, readjust, test again. Be sure to set aside time for this and assign the integrator a point of contact from your team who is familiar with the process and can make decisions.
Once the system is running stably, the Site Acceptance Test (SAT)—the binding acceptance test at your facility—follows. Here, under real-world conditions, it is verified that the system meets the contractually agreed-upon performance metrics. The SAT is the point at which responsibility formally transfers to the operator, and a payment installment is usually due.
Measurements are usually taken over a defined period of time or for a defined number of units. The following are typically checked:
A system is of little use if no one knows how to operate it. That’s why commissioning includes training your employees—operators, setup technicians, and maintenance staff. Well-trained staff can resolve minor malfunctions on their own, set up new part variants, and avoid costly service calls.
At the same time, the supplier hands over the documentation: operating instructions, maintenance schedule, electrical and mechanical drawings, risk assessment, and CE declaration of conformity. Make sure you also receive the programs, parameter sets, and access data—otherwise, you’ll be dependent on the supplier for every change.
There’s no one-size-fits-all answer—the duration depends on the complexity. As a rough guide, you can use the following estimates:
| Complexity | Example | On-site Duration (Guideline) |
|---|---|---|
| Simple | Standardized pick-and-place, one component | A few days to 1 week |
| Medium | Palletizing with multiple variants | 1–3 weeks |
| Complex | Image processing, high variety of variants, MES integration | Several weeks to months |
These figures apply to the on-site phase. Be sure to factor in FAT, transportation, and training as well. More important than the sheer duration is the stability achieved in the end: A slightly longer commissioning period that results in a reliably running process is more cost-effective than a rushed ramp-up with persistent malfunctions.
Most delays during commissioning stem from recurring causes. If you’re aware of them, you can take steps to prevent them:
Commissioning is the crucial phase in which a planned robot solution becomes a fully operational system. It proceeds in clear steps: factory acceptance testing at the supplier’s site, on-site installation and connection, iterative commissioning in your environment, final acceptance, and finally training and handover.
With a turnkey solution, the primary responsibility lies with the supplier—but your contribution plays a decisive role in determining success: a prepared production facility, representative test parts, clearly defined acceptance criteria, and a dedicated point of contact. Meeting these requirements significantly shortens the ramp-up phase and allows you to start reliable series production more quickly.