A Physical Configuration Audit (PCA) is a formal technical review that determines if the configuration of a system or item has met its documented requirements to establish a product baseline. The Milestone Decision Authority (MDA) receives proof from a successful PCA that the product design is stable, the capability satisfies end-user needs, and the production risks are tolerably low.

Checklist: Physical Configuration Audit Checklist – Sept 2017

Purpose of a Physical Configuration Audit (PCA)

The purpose of a PCA is to resolve any discrepancies between the production-representative item that has successfully passed Operational Test and Evaluation (OT&E) and the associated documentation currently under configuration control.

A successful PCA provides the Milestone Decision Authority (MDA) with evidence that the product design is stable, the capability meets end-user needs, and production risks are acceptably low.

When to Conduct a Physical Configuration Audit (PCA)

The PCA is conducted prior to the Full-Rate Production Decision Review (FRP DR) during the Production and Deployment (P&D) phase. Smaller elements within the design may have a PCA audit prior to the full system PCA.

A PCA performed during FRP can lose the chance to prevent expensive manufacturing flaws. Even though the system-level PCA usually comes before the FRP DR, other system-element PCAs may be performed at different times before the system-level PCA.

Physical Configuration Audit (PCA) Results

The information that is gathered from a PCA helps in the Full-Rate Production Decision Review (FRP DR) to determine if the system should go into full production. The key information that the PCA provides is:

• Verify all test deficiencies been resolved.
• The product baseline is stable and all changes after the PCA have been approved and incorporated.
• All production-related activities can produce an accurate design.
• Software and hardware have an established product baseline
• The manufacturing, quality, test & evaluation, training processes are in place.
• The product baseline information appropriately represents all hardware and software CIs.
• The manufacturing procedures, the quality assurance system, the testing and measuring tools, and the training are all properly designed, monitored, and regulated.

AcqLinks and References:

• Physical Configuration Audit Checklist – Sept 2017
• DAG CH 3-3.3.8 Physical Configuration Audit

Updated: 6/25/2021

Rank: G4.5