Configuration Verification & Audit

FCA & PCA
Configuration Audits

Comprehensive audit support for Functional Configuration Audits (FCA) and Physical Configuration Audits (PCA) aligned with EIA-649, AS9100, and MIL-HDBK-61B standards.

FCA
Functional Baseline
PCA
Product Baseline
100%
Traceability
DCMA
Audit Ready

Functional Configuration Audit (FCA)

The FCA verifies that all contractual, system, subsystem, and component-level requirements have been fully satisfied and verified using approved methods. The FCA establishes the Functional Baseline.

Purpose

Verify that the system meets all specified functional, performance, and interface requirements defined in the contract and technical specifications.

Outputs

  • • FCA Report
  • • Approved Functional Baseline
  • • Authorization to proceed to PCA

FCA Required Inputs & Artifacts

Contract, SOW, SOO
System & Subsystem Specifications
Interface Control Documents (ICDs)
Requirements Traceability Matrix (RTM)
Verification Cross-Reference Matrix (VCRM)
Approved Verification Methods (Test, Analysis, Inspection, Demonstration)
Approved Test Plans & Procedures
Test Reports, Logs, and Data Packages
Analysis Reports
Software Configuration Index (SCI)
Discrepancy Reports & Corrective Actions

FCA Focus Areas

  • Complete requirement-to-verification traceability
  • Approval status of all verification procedures
  • Closure of all test anomalies
  • Verification of performance margins
  • Software and firmware version alignment
  • Configuration control of test articles

FCA Entrance Criteria

  • Baselined requirements approved
  • Approved test procedures available
  • RTM/VCRM complete and reviewed
  • All planned verification activities complete

FCA Exit Criteria

  • All requirements verified and closed
  • All discrepancies resolved or approved
  • FCA report approved by stakeholders
  • Functional Baseline established

Physical Configuration Audit (PCA)

The PCA verifies that the as-built, as-configured product matches the approved design documentation and that all engineering changes have been properly incorporated. The PCA establishes the Product Baseline.

Purpose

Verify that the as-built product configuration exactly matches the approved engineering documentation.

Outputs

  • • PCA Report
  • • Approved Product Baseline
  • • Authorization for production or delivery

PCA Required Inputs & Artifacts

Approved Drawings and Models
Effectivity-Controlled Revisions
As-Built BOM (Serialized)
Manufacturing Travelers / Routers
Work Instructions Used
Part Traceability Records
Approved ECPs, ECOs, ECNs
Deviations and Waivers
FAI and Inspection Records
Software/Firmware Load Identification
Identification & Marking Records

PCA Focus Areas

  • Part numbers, dash numbers, revisions accuracy
  • Material and finish compliance verification
  • Hardware/software configuration alignment
  • Proper incorporation of all approved changes
  • Closure of all temporary deviations
  • Configuration identification and labeling

PCA Entrance Criteria

  • FCA successfully completed
  • All drawings released and approved
  • All engineering changes incorporated
  • As-built documentation available

PCA Exit Criteria

  • PCA report approved by all stakeholders
  • All discrepancies resolved or dispositioned
  • Product Baseline approved and released
  • Authorization for production or delivery granted

Common Audit Findings

Reference guide for typical findings identified during FCA/PCA audits. Use this to prepare and prevent common issues.

ECP approved but not incorporatedHIGH
BOM does not match as-builtHIGH
Missing traceability linksMEDIUM
Unapproved test proceduresHIGH
Software version mismatchesMEDIUM
Open deviations at PCAMEDIUM
Drawing revisions not incorporatedHIGH
Incomplete traceability matricesMEDIUM

Best Practices

Conduct internal mock FCA/PCA audits before customer audits
Maintain real-time configuration status accounting
Close all FCA findings before initiating PCA
Use standardized audit checklists for consistency
Maintain strict change discipline throughout program
Ensure entrance and exit criteria are clearly defined

Roles & Responsibilities

Configuration Management

  • Baseline control
  • Status accounting
  • Audit coordination

Systems Engineering

  • Requirements verification
  • RTM/VCRM ownership
  • Interface control

Quality

  • Inspection records
  • FAI support
  • Discrepancy tracking

Manufacturing

  • As-built records
  • Process documentation
  • Traveler management

Applicable Standards & References

EIA-649 / EIA-649-1A

Configuration Management Standard

AS9100 / AS9145

Aerospace Quality Management

MIL-STD-973

Legacy CM Reference

ISO/IEC/IEEE 15288

Systems Engineering

Ready to Manage Your Audits?

Access the full FCA/PCA audit management capabilities in the Baselinx dashboard.

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