Configuration Audit
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Configuration Audit Under GJB9001C
Configuration audit is the formal activity of verifying that a product conforms to its approved technical state documentation. GJB9001C Clause 8.1(i) requires organizations to "implement configuration identification, control, accounting, and audit" in accordance with GJB 3206. Configuration audit is the fourth and final core activity of technical state management — it provides the objective evidence that the product meets its requirements and that all changes have been properly implemented.
For PCB manufacturers, configuration audits verify that the manufactured board matches the approved Gerber files, fabrication drawings, and assembly documentation; that electrical and mechanical performance meets the functional baseline; and that all engineering changes have been correctly incorporated. Two types of configuration audits are required: Functional Configuration Audit (FCA) and Physical Configuration Audit (PCA). This guide provides a complete implementation roadmap covering audit types, planning, execution, reporting, corrective action, and audit preparation.
Engineering Summary
- Configuration audit is one of the four core activities of technical state management: identification, control, accounting, and audit.
- GJB9001C Clause 8.1(i) requires organizations to implement configuration audit per GJB 3206.
- Two audit types: Functional Configuration Audit (FCA) — verifies performance against functional baseline; Physical Configuration Audit (PCA) — verifies physical product against product baseline.
- FCA is typically conducted during qualification testing; PCA is typically conducted during First Article Inspection (FAI).
- Audit outputs include formal audit reports, nonconformance records, corrective action plans, and disposition decisions.
- For PCB manufacturers, FCA covers electrical performance, impedance, signal integrity; PCA covers dimensional compliance, material verification, and workmanship.
1. What External Auditors Check — A Quick Overview
| Audit Focus | What External Auditors Verify | Expected Evidence |
|---|---|---|
| Audit Planning | Is a configuration audit plan established and implemented? | Audit plan, schedule, resource allocation |
| FCA Performance | Has a Functional Configuration Audit been conducted to verify performance against requirements? | FCA plan, test reports, qualification records, audit report |
| PCA Performance | Has a Physical Configuration Audit been conducted to verify product against documentation? | PCA plan, FAI reports, inspection records, audit report |
| Nonconformance Management | Are audit nonconformances properly documented and resolved? | Nonconformance records, corrective action plans, verification records |
| Audit Reporting | Are audit reports complete, accurate, and communicated to stakeholders? | Audit reports, distribution records, management review inputs |
| Traceability | Is audit traceability maintained from requirements through verification? | Requirements traceability matrices, verification records, audit trails |
KEY INSIGHT:
Configuration audit is the ultimate verification that the product conforms to its baselines. Without formal FCA and PCA, organizations cannot demonstrate that the product meets customer requirements and technical state documentation.
2. Standard Requirements for Configuration Audit
2.1 GJB9001C — The Foundational Requirement
GJB9001C-2017 Clause 8.1(i) establishes the foundational requirement: "In accordance with GJB 3206, determine technical state baselines and their technical state items, prepare a technical state management plan, and implement technical state identification, control, accounting, and audit". This requirement makes configuration audit mandatory for all organizations in the military supply chain.
Additionally, Clause 8.3.4 (design and development verification) and Clause 8.3.5 (design and development validation) provide the framework for verifying and validating that design outputs meet requirements — which are the basis for configuration audit activities.
2.2 GJB 3206B — The Technical State Management Framework
GJB 3206B-2022 defines technical state verification and audit as the fourth core activity of technical state management. It requires that:
- Configuration audits are conducted to verify that the product conforms to its technical state documentation
- Functional Configuration Audit (FCA) is conducted to verify that the product's functional characteristics meet the functional baseline requirements
- Physical Configuration Audit (PCA) is conducted to verify that the product's physical characteristics match the product baseline documentation
- Audit results are documented and communicated
- Nonconformances are resolved and verified
2.3 GJB 908 — First Article Inspection
GJB 908 is the Chinese military standard for First Article Inspection (FAI). It provides specific requirements for verifying that the first production article conforms to design requirements. FAI is the primary mechanism for conducting the Physical Configuration Audit (PCA) in PCB manufacturing. GJB 908 aligns with international standards such as AS9102 and provides a structured approach to FAI including:
- FAI planning and preparation
- Characteristic verification (dimensional, material, performance)
- Documentation requirements (FAI report, measurement results, nonconformance records)
- FAI acceptance criteria
- FAI for changes (delta FAI)
2.4 The Configuration Audit Lifecycle
Configuration audits are typically conducted at specific lifecycle milestones:
- Functional Configuration Audit (FCA): Typically conducted during qualification testing, before production release. Verifies that the design meets functional and performance requirements.
- Physical Configuration Audit (PCA): Typically conducted during First Article Inspection (FAI) on the first production article. Verifies that the manufactured product matches the product baseline documentation.
- Follow-up audits: Conducted when changes are made to the technical state, to verify that changes have been correctly implemented and that product conformity is maintained.
3. Audit Types — Functional Configuration Audit vs. Physical Configuration Audit
| Aspect | Functional Configuration Audit (FCA) | Physical Configuration Audit (PCA) |
|---|---|---|
| Purpose | Verify that the product's functional and performance characteristics meet the functional baseline requirements | Verify that the physical product matches the product baseline documentation |
| Baseline Compared | Functional Baseline | Product Baseline |
| Timing | During qualification testing, before production release | During First Article Inspection, before full production release |
| Key Activities | Electrical testing, impedance verification, signal integrity testing, thermal cycling, environmental testing, reliability testing | Dimensional inspection, material verification, workmanship inspection, assembly verification, BOM verification |
| PCB Examples | Impedance test results, insertion loss measurements, thermal cycle test, signal integrity measurements | Gerber file comparison, dimensional measurements, laminate verification, solder joint inspection |
| Output | FCA report, test records, qualification summary | PCA report, FAI report, inspection records |
| Customer Involvement | Typically requires customer witness or approval | Typically requires customer witness or approval |
CRITICAL RULE:
Both FCA and PCA must be completed before production release. FCA verifies performance; PCA verifies physical conformity. Neither can substitute for the other — both are mandatory.
4. Configuration Audit Process — The Eight Steps
A structured configuration audit process ensures consistent and effective verification of product conformity. The following steps apply to both FCA and PCA.
| Step | Activity | PCB Example |
|---|---|---|
| 1 | Plan the Audit — Define audit scope, objectives, criteria, schedule, resources, and team. Identify required participants (design, quality, production, customer). | Plan FAI for PCB assembly; define inspection points; schedule customer witness; prepare FAI package. |
| 2 | Prepare Audit Documentation — Gather all required technical state documentation: functional baseline, product baseline, change records, and previous audit results. | Assemble customer specification, Gerber files, fabrication drawing, BOM, change notices, previous FAI reports (if applicable). |
| 3 | Conduct Pre-Audit Review — Review documentation for completeness and consistency. Verify that all changes have been correctly incorporated into baseline documentation. | Verify that Gerber files match fabrication drawing; check that ECN-2026-045 trace width change is reflected in both documents. |
| 4 | Execute the Audit — Perform verification activities per the audit plan. For FCA: conduct tests and measurements. For PCA: conduct inspections and measurements. Document all results. | Measure PCB dimensions against fabrication drawing; verify impedance against specification; inspect solder joints; perform electrical test. |
| 5 | Document Nonconformances — Record any deviations from requirements. Classify nonconformances by severity. Initiate nonconformance reports. | Trace width measurement out of tolerance — record nonconformance; initiate corrective action. |
| 6 | Analyze and Resolve Nonconformances — Determine root cause; develop corrective actions; implement and verify corrective actions; re-inspect or re-test as needed. | Investigate etching process variance; adjust process; retest trace width; verify compliance. |
| 7 | Issue Audit Report — Prepare formal audit report summarizing audit scope, activities, findings, nonconformances, corrective actions, and conclusion. Include recommendation for disposition. | Issue FAI report with measurement results, nonconformance resolution, and recommendation for production release. |
| 8 | Obtain Approval — Submit audit report to customer (if required) for approval. Upon approval, proceed to production release. Update configuration status accounting with audit results. | Submit FAI package to customer; obtain customer sign-off; update configuration status accounting record; release to production. |
5. PCB Configuration Audit Scenarios — Practical Examples
5.1 Functional Configuration Audit (FCA) — PCB Performance Verification
| Item | Description |
|---|---|
| Scope | Verify that PCB electrical performance meets functional baseline requirements |
| Baseline Reference | Functional baseline: customer specification, impedance requirements, signal integrity requirements, reliability requirements |
| Verification Activities | Impedance testing (50Ω single-ended, 100Ω differential); insertion loss measurement; signal integrity analysis; thermal cycling test; CAF resistance test; environmental screening |
| Acceptance Criteria | All measurements within specification limits; all test pass criteria met; no failures in environmental screening |
| Output | FCA test report; qualification summary; approval for production release |
5.2 Physical Configuration Audit (PCA) — PCB First Article Inspection
| Item | Description |
|---|---|
| Scope | Verify that the manufactured PCB matches product baseline documentation |
| Baseline Reference | Product baseline: Gerber files, fabrication drawing, assembly drawing, BOM, test specifications |
| Verification Activities | Dimensional measurement (board size, hole locations, trace widths); material verification (laminate type, copper weight, surface finish); workmanship inspection (soldermask, legend); assembly verification (component placement, BOM accuracy) |
| Acceptance Criteria | All dimensions within tolerances; material certifications match; workmanship meets IPC-6012 Class 3; BOM components verified |
| Output | PCA report; FAI package (per GJB 908); approval for production release |
5.3 Delta Audit — Change-Driven Re-Audit
| Item | Description |
|---|---|
| Trigger | Material substitution (Class I change) approved and implemented |
| Scope | Verify that the change has been correctly implemented and that product conformity is maintained |
| Verification Activities | Review updated baseline documentation; verify material certification; conduct targeted functional testing (impedance, thermal cycling); conduct targeted physical inspection (dimensions, workmanship) |
| Acceptance Criteria | All change-related requirements met; no adverse effects on form, fit, function, reliability |
| Output | Delta FAI report; updated configuration status accounting; approval for continued production |
6. Key Control Points in PCB Configuration Audit
6.1 Audit Planning and Scheduling
- Define audit scope and objectives in the technical state management plan
- Schedule audits at appropriate lifecycle milestones (PDR, CDR, production release)
- Allocate adequate resources (personnel, equipment, time)
- Coordinate with customers for witness or approval requirements
- Establish audit team with appropriate technical expertise
6.2 Audit Documentation
- Ensure baseline documentation is current and complete before audit
- Verify that all changes have been correctly incorporated into baseline documentation
- Prepare audit checklists based on baseline requirements
- Use standardized FAI forms (e.g., GJB 908 forms, AS9102 forms)
- Maintain complete audit trail from requirements through verification
6.3 Measurement and Test Equipment
- Ensure all measurement and test equipment is calibrated and traceable
- Maintain calibration records for all equipment used in audits
- Use approved test methods and procedures
- Document measurement uncertainty where applicable
- Retain test and measurement records
6.4 Nonconformance Management
- Document all nonconformances with clear description and classification
- Conduct root cause analysis for all nonconformances
- Develop and implement corrective actions
- Verify effectiveness of corrective actions through re-inspection or re-test
- Record disposition decisions (accept, reject, rework, scrap)
- Obtain customer approval for nonconformance disposition if required
6.5 Audit Reporting and Approval
- Prepare formal audit reports that include all required information
- Include audit scope, objectives, criteria, activities, findings, nonconformances, corrective actions, and conclusion
- Submit audit reports to customers for approval (if required)
- Maintain audit reports in configuration status accounting
- Update configuration status accounting with audit results and approval
6.6 Delta FAI
- Conduct delta FAI when changes are made to the technical state
- Scope delta FAI to only the characteristics affected by the change
- Maintain traceability from change to delta FAI
- Document delta FAI results and obtain approval
- Update configuration status accounting
7. Audit Preparation Checklist for PCB Manufacturers
| # | Check Item | Clause | Status | Notes |
|---|---|---|---|---|
| Audit Planning | ||||
| 1 | Configuration audit plan is established and documented | GJB 3206B | ☐ | |
| 2 | Audit schedule is established and communicated | GJB 3206B | ☐ | |
| FCA | ||||
| 3 | Functional Configuration Audit has been conducted | GJB 3206B | ☐ | |
| 4 | FCA test and qualification records are maintained | 8.3.4 | ☐ | |
| PCA | ||||
| 5 | Physical Configuration Audit (FAI) has been conducted | GJB 3206B | ☐ | |
| 6 | FAI per GJB 908 requirements is completed | GJB 908 | ☐ | |
| Nonconformance Management | ||||
| 7 | Audit nonconformances are documented | 8.7 | ☐ | |
| 8 | Nonconformances are resolved and verified | 8.7 | ☐ | |
| Audit Reporting | ||||
| 9 | Audit reports are complete and accurate | GJB 3206B | ☐ | |
| 10 | Audit reports are approved by customer (if required) | GJB 3206B | ☐ | |
| Traceability and Status Accounting | ||||
| 11 | Audit results are recorded in configuration status accounting | GJB 3206B | ☐ | |
| 12 | Traceability is maintained from requirements through audit verification | GJB 3206B | ☐ | |
| Delta Audits | ||||
| 13 | Delta audits are conducted for changes affecting technical state | GJB 3206B | ☐ | |
| 14 | Delta audit results are documented and approved | GJB 3206B | ☐ | |
8. Common Audit Findings and How to Avoid Them
| Finding | Why It Happens | How to Avoid |
|---|---|---|
| "No configuration audit plan" | Audit activities not formally planned | Document audit plan in technical state management plan; schedule audits at milestones |
| "FCA not conducted" | Functional performance not verified against baseline | Conduct FCA during qualification testing; document results |
| "PCA not conducted" | Physical product not verified against documentation | Conduct PCA (FAI) before production release; document results |
| "Nonconformances not resolved" | Audit findings not properly addressed | Implement corrective action process; verify effectiveness |
| "No audit reports" | Audit results not documented | Prepare formal audit reports; maintain in configuration status accounting |
| "Customer approval not obtained" | Audit reports not submitted for customer approval | Submit FCA and PCA reports to customer; obtain approval before production release |
| "No delta audit for changes" | Changes implemented without re-verification | Conduct delta FAI for all changes affecting technical state |
| "Audit traceability missing" | No traceability from requirements to audit results | Maintain requirements traceability matrix; link audit results to requirements |
9. Frequently Asked Questions
What is a configuration audit?
A configuration audit is the formal activity of verifying that a product conforms to its approved technical state documentation. It is one of the four core activities of technical state management.
What are the two types of configuration audit?
Functional Configuration Audit (FCA) verifies that product performance meets the functional baseline. Physical Configuration Audit (PCA) verifies that the physical product matches the product baseline documentation.
When is FCA conducted?
FCA is typically conducted during qualification testing, before production release. It verifies that the design meets functional and performance requirements.
When is PCA conducted?
PCA is typically conducted during First Article Inspection (FAI) on the first production article. It verifies that the manufactured product matches the product baseline documentation.
What is the difference between FCA and PCA?
FCA verifies performance against functional requirements; PCA verifies physical conformity against documentation. Both are mandatory — neither can substitute for the other.
What is a delta audit?
A delta audit is a targeted re-audit conducted when changes are made to the technical state. It verifies that the change has been correctly implemented and that product conformity is maintained.
What is the relationship between FAI and PCA?
First Article Inspection (FAI) per GJB 908 is the primary mechanism for conducting the Physical Configuration Audit (PCA). FAI provides the structured approach to verifying the first production article against product baseline documentation.
What should be included in a configuration audit report?
An audit report should include: audit scope, objectives, criteria, activities, findings, nonconformances, corrective actions, conclusion, and recommendation for disposition.
Related Standards & Topics
PCB Manufacturing for Military and Aerospace Programs
UltroNiu Electronics Group provides PCB and PCBA manufacturing services under GJB9001C-compliant configuration audit practices. Contact our engineering team for program-specific audit planning and verification requirements.
Request Engineering ReviewReferences: GJB9001C-2017 Clauses 8.1(i), 8.3.4, 8.3.5 (Central Military Commission Equipment Development Department); GJB 3206B-2022 Technical State Management; GJB 908-2010 First Article Inspection for Products of Weapons and Equipment. Technical state management four-activity framework and configuration audit requirements sourced from GJB 3206B-2022. FCA and PCA definitions and requirements sourced from GJB 3206B-2022 implementation guidance. FAI requirements and practices sourced from GJB 908-2010. PCB-specific configuration audit practices based on industry best practices for military and aerospace PCB manufacturing. Courtesy of UltroNiu Engineering Knowledge Center.
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