Verification, FAT, SAT & Commissioning

Verification proves requirements; validation proves the solution serves the intended work. Build the test matrix from the requirement IDs, not from whatever is easiest to demonstrate.

Evidence types

• inspection: identity, dimensions, workmanship, configuration, documentation;
• analysis: loads, margins, timing, heat, flow, capacity, uncertainty;
• simulation: logic, collision, trajectories, production variability, fault paths;
• component/subsystem test: uncertain physics and interfaces;
• FAT: integrated functions before site release;
• SAT: installed functions, utilities, interfaces, site hazards, and acceptance;
• performance qualification: representative mix over time with intended staffing.

NIST couples real and virtual testing with metrics and protocols ¹. NIST also warns that digital models need verification, validation, and uncertainty quantification ².

Test-case anatomy

State ID, requirement, preconditions, configuration, equipment, calibrated instruments, personnel/roles, procedure, data, expected result, acceptance threshold, stop criteria, restoration, and discrepancy handling. Preserve raw evidence.

Fault and recovery campaign

Test missing part, wrong part, sensor disagreement, jam, low pressure, drive fault, communications loss, power interruption, restart, full buffer, unavailable downstream, failed calibration check, and attempted invalid command. Use safe simulations or bounded methods; never create uncontrolled hazardous states.

Commissioning release

Use a punch list with severity. Define which items block shipment, power-on, automatic mode, personnel access, production, or final acceptance. Verify training, procedures, spares, backups, restoration, maintenance, safety validation, and ownership before release.

Gate 5

Pass when every critical requirement has accepted evidence, every high-severity discrepancy is closed, configuration matches the record, recovery is demonstrated, and responsible authorities approve release.