Configuration Change Control (PCN)
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Configuration Change Control (PCN) Under GJB9001C
Configuration change control — embodied in the Product Change Notification (PCN) process — is the formal mechanism for managing changes to the approved technical state of a product throughout its lifecycle. Under GJB9001C, change control requirements are embedded across multiple clauses: Clause 8.3.6 (design and development changes), Clause 8.5.6 (change control for production and service provision), and Clause 8.2.4 (changes to product/service requirements). When changes affect product technical state, they must be controlled in accordance with GJB 3206B technical state management requirements.
For PCB manufacturers, configuration change control means systematically managing every change that affects the product's technical state — from component substitutions and material changes to process optimizations and customer requirement updates. The PCN is the formal notification that communicates approved changes to all affected stakeholders, including customers, ensuring traceability, accountability, and continued product conformity. This guide provides a complete implementation roadmap covering the four change clauses, technical state change classification, the six principles, the seven-step PCN process, PCB-specific scenarios, and audit preparation.
Engineering Summary
- GJB9001C contains four change clauses: 6.3 (QMS changes), 8.2.4 (requirement changes), 8.3.6 (design changes), and 8.5.6 (production changes).
- Technical state changes are classified into Class I, II, and III per GJB 3206B — approval requirements escalate with impact level.
- Six principles govern configuration change control: classification accuracy, sufficient justification, test verification, stakeholder consensus, complete approval, and full implementation.
- The PCN process follows seven steps: determine need, submit application, evaluate and review, approve and decide, prepare notice, implement change, and confirm completion.
- For PCB manufacturers, PCN covers component substitutions, material changes, Gerber revisions, process optimizations, and customer requirement changes.
- Class I changes (affecting form, fit, function, reliability, safety) require customer approval; Class III changes (documentation corrections) may follow simplified internal procedures.
1. What Auditors Check — A Quick Overview
| Audit Focus | What External Auditors Verify | Expected Evidence |
|---|---|---|
| Change Identification | Are configuration changes properly identified and documented? | Change requests, ECR/ECO/PCN records |
| Change Classification | Are changes correctly classified as Class I, II, or III? | Classification records, justification documentation |
| Change Review & Evaluation | Are changes reviewed for impact on form, fit, function, reliability, safety, and cost? | Impact analysis reports, review minutes, test records |
| Change Approval | Are changes approved by authorized personnel before implementation? | Approval signatures, authorization records |
| Customer Consent | Is customer consent obtained for Class I changes and baseline-affecting changes? | Customer approval records, PCN acknowledgement |
| PCN Communication | Are PCNs issued to all affected stakeholders with adequate notice? | PCN distribution records, customer acknowledgement |
| Implementation & Tracking | Are changes properly implemented and tracked? | Updated documentation, revision history, implementation records |
| Documented Information | Are records of changes, reviews, approvals, and actions retained? | Change control records, PCN files, configuration status accounting |
KEY INSIGHT:
Configuration change control is the most frequently audited area in configuration management. Auditors will verify that every change is properly classified, reviewed, approved, communicated via PCN, implemented, and recorded.
2. The Four "Change" Clauses in GJB9001C — Understanding the Differences
GJB9001C-2017 contains four distinct clauses addressing changes, each with different scope and requirements. Understanding which clause applies is essential for proper configuration change control.
| Clause | Scope | Description | PCB Application |
|---|---|---|---|
| 6.3 | Quality Management System | Changes to the QMS itself — organizational structure, processes, resources. Requires planned implementation considering purpose, consequences, system integrity, resources, and responsibilities. | Reorganizing the quality department, updating the document control system |
| 8.2.4 | Customer Requirements | Changes to product/service requirements — may originate from customer or organization. Requires review, documented information updates, and notification to all affected personnel. | Customer changes impedance requirement from 50Ω to 55Ω |
| 8.3.6 | Design & Development | Changes to design and development outputs throughout the lifecycle. Requires identification, review, control, and documented information. Design changes must comply with technical state management requirements. | Gerber file updates, stackup revisions, material substitutions |
| 8.5.6 | Production & Service | Changes during production and service provision. Requires review and control to ensure continued conformity. | Process parameter adjustments, equipment changes, inspection method updates |
For changes involving product technical state, they must be controlled according to technical state change requirements and incorporated into technical state management For changes not involving product technical state, review, verification, validation, and approval are still required before implementation.
3. Technical State Change Classification — Class I, II, and III
Under GJB 3206B, technical state changes are classified into three categories based on impact level. Classification determines the approval authority and customer notification requirements.
3.1 Class I Changes (Major Changes)
Changes involving product functional and physical characteristics that affect reliability, safety, environmental adaptability, or performance after design finalization.
- PCB Examples: Material substitution (FR4 to high-frequency material), layer count change, impedance value change, surface finish change (ENIG to ENEPIG), critical dimension changes affecting fit or function
- Approval: Requires customer approval.Class I change applications must be approved by the procuring party.
3.2 Class II Changes (General Changes)
General technical state changes that do not reach the impact level of Class I changes.
- PCB Examples: Minor material changes within approved families, process optimization not affecting electrical performance, non-critical dimensional adjustments, tolerance adjustments within specification limits
- Approval: For pre-design-finalization Class II changes, the contractor may self-approve and notify the customer.For post-design-finalization Class II changes, customer approval is required.
3.3 Class III Changes (Minor Changes)
Low-level technical changes that do not affect product quality or requirements fulfillment.
- PCB Examples: Errata corrections in documentation, drawing clarification, uniform annotation method updates, typographical corrections, non-technical clarifications
- Approval: Contractor may self-approve; no customer approval required. Class III changes may follow a simplified four-step procedure.
4. The Six Principles of Configuration Change Control
GJB 3206B establishes six core principles for technical state change control that organizations must follow.
| Principle | Description | PCB Manufacturing Application |
|---|---|---|
| Classification Accuracy | Changes must be accurately classified according to definitions; classification cannot be arbitrarily changed | Properly classify PCB changes — don't downgrade a material substitution (Class I) to Class II to bypass approval |
| Sufficient Justification | Before submitting a change request, the proposing party must conduct comprehensive justification of necessity, correctness, and feasibility | Document why the PCB change is needed — cost reduction, supply chain issues, performance improvement — with supporting data |
| Test Verification | Verify the change plan through testing to confirm correctness, feasibility, and effectiveness | Conduct impedance testing, thermal cycling, or reliability testing to validate the change |
| Stakeholder Consensus | All affected departments and technical systems must have clear understanding and consensus on necessity and feasibility | Involve design, production, quality, procurement, and customer in the review process |
| Complete Approval | All affected technical state documents must be reviewed and approved according to defined responsibilities and procedures | Ensure all signatures are obtained — engineering manager, quality, customer (if required) |
| Full Implementation | All affected departments must implement and execute approved changes — including document updates, product realization, and supervision | Update Gerber files, fabrication drawings, BOMs, inspection criteria; train operators; verify first articles |
5. Configuration Change Control (PCN) Process — The Seven Steps
The technical state change basic procedure consists of seven steps, from identifying the need through confirming completion.
| Step | Activity | PCB Example |
|---|---|---|
| 1 | Determine the Need — Any stakeholder may propose a change. Change category is generally determined by the contractor, with procuring party providing final confirmation if disagreements arise. | Customer requests impedance change; production identifies material availability issue; quality identifies reliability concern |
| 2 | Submit Application — For Class I and II changes, prepare a change application document. Class III changes may proceed directly to a change notice. Application must have a unique identifier. | Submit ECR with change description, justification, impacted documents (Gerber, stackup, BOM), and supporting data |
| 3 | Evaluate and Review — Different change categories require different review methods — meetings, counter-signatures, or hierarchical approval. Assess impact on product use, user requirements, schedule, cost, methods, and resources. | Cross-functional review involving design, production, quality, procurement, and cost control. Assess electrical performance risk, supply chain impact, process compatibility, and cost Change |
| 4 | Approve and Decide — Approval is required before implementation. For Class I and II changes, complete internal approval first, then external approval. | Obtain approval signature from appropriate authority. For Class I changes, obtain customer approval |
| 5 | Prepare Change Notice (PCN) — For Class I and II changes, prepare the change notice based on the approved application. The PCN is the formal notification to all affected stakeholders. | Issue PCN with Take effect batch numbers, affected document list, implementation instructions, and customer notification |
| 6 | Implement the Change — Includes document updates (Gerber, drawings, BOMs with version control), material transition, trial production verification, and production switch | Update Gerber files from V1.1 to V1.2; conduct trial run of 50 boards; perform impedance testing; update inspection criteria; verify first article |
| 7 | Confirm Completion — Mark change batches with special labels; record change Take effect serial number range; verify effectiveness; update configuration status accounting | Label change batches with PCN reference; track quality metrics for 3 production batches; document effectiveness in closure report |
CRITICAL RULE:
Changes must not be implemented before approval is obtained. "No approval, no implementation" is the fundamental rule of configuration change control.
6. PCB Configuration Change Scenarios — Practical PCN Examples
6.1 Component Substitution PCN
| Item | Description |
|---|---|
| Trigger | Supplier EOL notice for ceramic capacitor — 100nF, 50V, X7R, 0805 |
| Classification | Class I — affects form (footprint change from 0805 to 0603) and may affect reliability |
| PCN Actions | Submit ECR with impact analysis; qualify alternative component; obtain customer approval; issue PCN with 90-day notice; update BOM and assembly drawing; conduct FAI |
| Documentation | ECR, qualification test report, customer approval, PCN, updated BOM, FAI report |
6.2 Material Change PCN
| Item | Description |
|---|---|
| Trigger | Laminate supplier discontinues a high-frequency material used in a military radar PCB |
| Classification | Class I — material change affects electrical and reliability characteristics |
| PCN Actions | Qualify alternative material; redesign stackup; requalify impedance and signal integrity; obtain customer approval; issue PCN; update stackup and Gerber files |
| Documentation | Material qualification report, test verification records, customer approval, PCN, updated stackup |
6.3 Process Change PCN
| Item | Description |
|---|---|
| Trigger | Soldermask application process optimized for better yield |
| Classification | Class II — process optimization not affecting form, fit, or function |
| PCN Actions | Conduct trial runs; verify solder mask adhesion and thickness; update process control documentation; issue PCN with customer notification |
| Documentation | Trial run records, verification test reports, PCN, updated process documents |
6.4 Customer Requirement Change PCN
| Item | Description |
|---|---|
| Trigger | Customer requests impedance change from 50Ω to 55Ω |
| Classification | Class I — affects electrical performance; requires redesign and requalification |
| PCN Actions | Review customer requirement change; update stackup and Gerber; conduct impedance verification testing; obtain customer approval; issue PCN; update fabrication drawing and inspection criteria |
| Documentation | Customer change request, updated Gerber files, test reports, PCN, revised fabrication drawing |
7. Key Control Points in PCB Configuration Change Control
7.1 Change Classification Accuracy
- Accurately classify changes as Class I, II, or III per GJB 3206B definitions
- Do not arbitrarily downgrade change classification to bypass approval requirements
- When classification is disputed, the procuring party/contract supervision agency makes the final determination
- Document classification rationale in the change application
7.2 PCN Notification and Communication
- Issue PCNs to all affected stakeholders, including customers, with adequate notice (typically 90 days for Class I changes)
- PCN must include: change description, reason for change, PCN tracking number, affected product identification, effective date, and recommended action
- Obtain customer acknowledgement of PCN receipt
- Maintain PCN distribution records
7.3 Change Justification and Verification
- Conduct comprehensive justification of necessity, correctness, and feasibility before submitting change request
- Perform test verification to confirm change correctness, feasibility, and effectiveness
- Document all verification activities and results
- For Class I changes, conduct system analysis and verification
7.4 Stakeholder Consensus and Approval
- Ensure all affected departments have clear understanding and consensus on necessity and feasibility
- Obtain complete approval signatures from all required authorities
- For Class I changes, obtain customer approval before implementation
- Document all approval decisions
7.5 Implementation and Traceability
- Update all affected documentation (Gerber files, fabrication drawings, BOMs, inspection criteria)
- Implement changes in production with proper version control
- Mark change batches for traceability (PCN reference, date code, serial number range)
- Record all changes in configuration status accounting
- Track change implementation effectiveness
8. Audit Preparation Checklist for PCB Manufacturers
| # | Check Item | Clause | Status | Notes |
|---|---|---|---|---|
| Change Identification & Classification | ||||
| 1 | Configuration change control procedure is documented and implemented | 8.3.6 | ☐ | |
| 2 | Changes are classified as Class I, II, or III per GJB 3206B | GJB 3206B | ☐ | |
| Change Review & Approval | ||||
| 3 | Change justification and impact analysis are documented | 8.3.6 | ☐ | |
| 4 | Change review records are maintained (meeting minutes, sign-offs) | 8.3.6 | ☐ | |
| 5 | Change approval is obtained before implementation | 8.3.6 | ☐ | |
| 6 | Customer approval is obtained for Class I changes | GJB 3206B | ☐ | |
| PCN Communication | ||||
| 7 | PCNs are issued for all configuration changes | GJB 3206B | ☐ | |
| 8 | PCNs are distributed to all affected stakeholders with adequate notice | GJB 3206B | ☐ | |
| 9 | Customer acknowledgement of PCN is obtained | GJB 3206B | ☐ | |
| Implementation & Verification | ||||
| 10 | Change implementation is tracked and verified | 8.3.6 | ☐ | |
| 11 | Test verification is conducted for significant changes | GJB 3206B | ☐ | |
| Documentation & Status Accounting | ||||
| 12 | All documentation is updated to reflect changes | 7.5.3 | ☐ | |
| 13 | Change records are retained (ECR, ECO, PCN, approval records) | 8.3.6 | ☐ | |
| 14 | Changes are recorded in configuration status accounting | GJB 3206B | ☐ | |
9. Common Audit Findings and How to Avoid Them
| Finding | Why It Happens | How to Avoid |
|---|---|---|
| "Changes not identified or documented" | Changes made informally without proper request documentation | Require ECR for all changes, no exceptions |
| "Changes not properly classified" | Class I changes downgraded to Class II to bypass approval | Follow GJB 3206B classification definitions; document classification rationale |
| "Changes implemented without approval" | Bypassing approval process to save time | Enforce "no approval, no implementation" rule |
| "Customer consent not obtained for Class I changes" | Not recognizing when changes require customer approval | Train staff on Class I classification and customer approval requirements |
| "PCNs not issued or not acknowledged" | Changes implemented without customer notification | Issue PCNs for all changes; obtain customer acknowledgement; maintain distribution records |
| "Insufficient change justification" | Changes made without proper necessity and feasibility analysis | Require comprehensive justification in every ECR; include supporting data |
| "No test verification for significant changes" | Assuming change is safe without testing | Require test verification for all Class I and Class II changes |
| "Changes not recorded in status accounting" | Changes implemented but not entered into configuration status accounting | Link change completion to status accounting update; make it a mandatory step |
10. Frequently Asked Questions
What is the difference between Clause 8.3.6 and Clause 8.5.6?
Clause 8.3.6 applies to design and development changes — changes to design outputs such as Gerber files, stackups, and specifications. Clause 8.5.6 applies to production and service provision changes — changes during manufacturing such as process parameters, equipment, and inspection methods.
What are the three classes of technical state change?
Class I: major changes affecting form, fit, function, reliability, safety, or environmental adaptability. Class II: general changes that do not reach Class I impact. Class III: minor changes that do not affect product quality or requirements fulfillment.
What changes require customer approval?
Class I technical state changes and Class II changes after design finalization require customer approval.Any change affecting baselines also requires customer consent.
What is a PCN?
A Product Change Notification (PCN) is a formal notice communicating approved configuration changes to all affected stakeholders, including customers. It must include change description, reason, affected products, effective date, and recommended action.
What are the six principles of configuration change control?
The six principles are: classification accuracy, sufficient justification, test verification, stakeholder consensus, complete approval, and full implementation.
What is the seven-step PCN process?
The seven steps are: determine need, submit application, evaluate and review, approve and decide, prepare notice (PCN), implement change, and confirm completion.
Can Class III changes follow a simplified process?
Yes. Class III changes may follow a simplified four-step procedure: determine need, prepare notice, implement change, and confirm completion.
What documented information must be retained for changes?
Organizations must retain records of: the change itself, review results, change authorization, and actions taken to prevent adverse effects.
Related Standards & Topics
PCB Manufacturing for Military and Aerospace Programs
UltroNiu Electronics Group provides PCB and PCBA manufacturing services under GJB9001C-compliant configuration change control. Contact our engineering team for program-specific PCN and change management requirements.
Request Engineering ReviewReferences: GJB9001C-2017 Clauses 6.3, 8.2.4, 8.3.6, 8.5.6 (Central Military Commission Equipment Development Department); GJB 3206B-2022 Technical State Management. Technical state change classification and six principles sourced from GJB 3206B-2022. Change control procedures and seven-step process sourced from GJB 3206B-2022 implementation guidance. PCN notification requirements based on industry best practices (J-STD-046, ZVEI guidelines). PCB-specific configuration change control practices based on industry best practices for military and aerospace PCB manufacturing. Courtesy of UltroNiu Engineering Knowledge Center.
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