4.2.16. Physical Configuration Audit

DEFENSE ACQUISITION GUIDEBOOK
Chapter 4 -- Systems Engineering

4.2.16. Physical Configuration Audit

4.2.16. Physical Configuration Audit

The Physical Configuration Audit (PCA) is a formal examination to verify the “to be fielded” configuration of a validated system against its design and manufacturing documentation. The objective of the 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. At the conclusion of the PCA, the final product baseline is established and all subsequent changes are processed by formal engineering change action. Further information can be found in MIL-HDBK-61A.

The PCA is an event-driven technical assessment and typically occurs during the Production and Deployment (P&D) phase, after successful system validation but prior to the Full-Rate Production Decision Review (FRP DR). A PCA conducted during FRP may miss the opportunity to avoid costly defects built into production. While the system-level PCA typically occurs before the FRP DR, other system element PCAs may be conducted at various points in advance of the system-level PCA.

A properly conducted and documented PCA provides a major knowledge point in preparation for investment decisions at FRP DR. The PCA confirms:

• Any testing deficiencies have been resolved and appropriate changes implemented; changes to the product baseline have been incorporated into current design documentation
• All production-related activities (tooling, acceptance/inspection equipment, instructions, molds, jigs, and make-buy decisions) are focused on a validated and accurate design
• Any system elements that were affected/redesigned after the completion of the Functional Configuration Audit (FCA) also meet contract requirements
• The manufacturing processes, quality control system, measurement and test equipment, and training are adequately planned, tracked, and controlled

Roles and Responsibilities

The unique Program Manager responsibilities associated with a system PCA include:

• Approve, fund, and staff the PCA as planned in the Systems Engineering Plan (SEP) developed by the Systems Engineer
• Establish the plan to FRP DR in applicable contract documents including the SE Management Plan (SEMP), Integrated Master Schedule (IMS), and Integrated Master Plan (IMP)
• Ensure the plan includes independent subject matter experts to participate in each review
• Determine if the readiness of manufacturing processes, quality management system, and production planning (i.e., facilities, tooling and test equipment capacity, personnel development and certification, process documentation, inventory management, supplier management, etc.) provide low-risk assurances for supporting FRP
• Continue to control Class I changes to the system product baseline (see DAG section 4.3.7. Configuration Management Process)

The unique Systems Engineer responsibilities associated with a system PCA include:

• Develop and execute the PCA plans with established quantifiable review criteria, carefully tailored to satisfy program objectives
• Coordinate with configuration management and manufacturing SMEs and the production contractor/production facility to develop an efficient approach to the PCA
• Identify method(s) of examining the production-representative item (e.g., disassembly, inspection, and reassembly) and verify the item against related design documentation
• Ensure that the pre-established review criteria have been met to ensure the production capability forms a satisfactory, affordable, and sustainable basis for proceeding with FRP
• Advise the Program Manager on whether production capability forms a satisfactory, affordable, and sustainable basis for proceeding into FRP
• Ensure adequate plans and resources are in place to get from PCA to Full Operational Capability (FOC)
• Ensure plans to get to FOC allow for contingencies
• Ensure production implementation supports overall performance and maintainability requirements
• Monitor and control the execution of the PCA closure plans

When the program does not plan to control the detailed design or purchase the item’s technical data, the developer should conduct an internal PCA to define the starting point for controlling the detailed design of the item and establishing a product baseline.

Inputs and Audit Criteria

Figure 4.2.16.F1 provides the end-to-end perspective and the integration of SE technical reviews and audits across the acquisition life cycle.

Figure 4.2.16.F1. Weapon System Development Life Cycle

The PCA criteria are developed to best support the program’s technical scope and risk and are documented in the program’s SEP no later than Milestone C. The PCA is conducted when these criteria are considered to be met.

Table 4.2.16.T1 defines the suggested PCA products and associated review criteria. The review should not begin until the Systems Engineer judges that all criteria have been met. The DoD PCA Checklist and can be used for assessing readiness for the audit. This is a best practice audit.

Table 4.2.16.T1. PCA Products and Criteria

Outputs and Products

The Technical Review Chair determines when the review is complete. The primary output of the PCA is a verified product baseline that accurately reflects the validated system and supports a favorable FRP DR.

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