As a Senior FAT/SAT Engineer, you will be responsible for independently leading and overseeing the entire lifecycle of Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) processes for high-performance packaging and filling machinery. You will play a key role in ensuring successful equipment validation, customer satisfaction, and operational excellence across multiple projects.
Lead FAT execution in the factory including coordination with design, automation, and QA/QC teams.
Manage SAT activities including on-site installation, commissioning, troubleshooting, and customer handover.
Supervise and mentor junior engineers and technicians during FAT/SAT processes.
Analyze and resolve complex mechanical, electrical, and automation-related issues during machine testing and startup.
Collaborate with cross-functional departments to ensure alignment on machine readiness, testing protocols, and customer requirements.
Ensure all work is performed in compliance with GMP, ISO, safety, and quality standards.
Provide strategic feedback to engineering and R&D teams for continuous product improvement.
Prepare and approve detailed documentation: test protocols (IQ/OQ/PQ), deviation logs, punch lists, final SAT reports.
Act as the primary technical liaison with customers, ensuring all deliverables meet project and operational expectations.
Conduct technical training sessions for customer operators, technicians, and maintenance teams.
End-to-End FAT/SAT Leadership
Own the planning, execution, and closure of all FAT/SAT activities.
Review and validate machine performance against URS/specifications before delivery and after installation.
Technical Expertise in Packaging & Filling Machinery
Deep knowledge of filling systems (e.g., volumetric, rotary, gravity, piston), packaging line integration, conveyors, labelers, etc.
Experience across multiple industries such as pharmaceutical, food & beverage, FMCG, dairy.
Automation & Controls Collaboration
Advanced understanding of PLC/HMI logic, servo systems, sensors, and electrical troubleshooting.
Coordinate with automation engineers to validate control sequences, alarms, and interlocks.
Customer Interaction & Satisfaction
Act as a trusted advisor and lead interface with client technical teams during trials and commissioning.
Handle escalations, drive resolutions, and ensure high levels of customer satisfaction.
Team Leadership & Project Ownership
Lead commissioning teams onsite, delegate tasks effectively, and ensure team adherence to safety and quality standards.
Maintain accountability for testing timelines, documentation accuracy, and successful project handover.
Compliance & Validation
Ensure compliance with validation protocols, particularly in regulated environments (e.g., pharma – cGMP, FDA, 21 CFR Part 11).
Support regulatory inspections and audits if required.
Continuous Improvement & Feedback
Provide structured feedback on design for manufacturability, serviceability, and operational efficiency.
Contribute to the development of standard FAT/SAT procedures and best practices documentation.
Education: Bachelor's Degree in Mechanical / Mechatronics / Electrical Engineering (Master’s preferred).
Experience: 7–12 years in commissioning, FAT/SAT, or service of packaging and filling machines.
Technical Skills:
Proficient in reading mechanical drawings, electrical schematics, and PLC logic.
Strong root cause analysis and system-level troubleshooting skills.
Soft Skills:
Leadership and mentoring capabilities.
Excellent communication, customer handling, and stakeholder management skills.
Travel: Willing to travel extensively based on project demands.