Configuration Management

Configuration Management (CM) is the systematic discipline for establishing, documenting, and controlling the functional and physical characteristics of a system throughout its lifecycle, ensuring that changes are evaluated, approved, implemented, and verified in a controlled manner on government contracts.

What is Configuration Management?

MIL-HDBK-61 and ANSI/EIA-649 define the principles and practices of configuration management for defense and government programs. CM encompasses four core activities: configuration identification (establishing and documenting the approved configuration of the system), configuration control (evaluating and approving proposed changes through a formal process before implementation), configuration status accounting (recording and reporting the current configuration and the history of approved changes), and configuration audits (verifying that the delivered system matches its documented configuration).

The configuration baseline is the foundation of CM. Three primary baselines are established for defense systems: the Functional Baseline (approved after the System Requirements Review, defining performance requirements), the Allocated Baseline (approved after the Preliminary Design Review, allocating requirements to subsystems), and the Product Baseline (approved after the Critical Design Review and testing, defining the as-built configuration). Changes to each baseline must go through the Configuration Control Board (CCB) before implementation.

Engineering Change Proposals (ECPs) are the formal mechanism for requesting changes to the approved configuration. Class I changes (affecting the form, fit, or function of an approved baseline) require government approval. Class II changes (minor, within approved tolerances) may be approved at the contractor level per the approved CM plan. The Technical Data Package (TDP) documents the current approved baseline.

Why configuration management matters for government contractors

Inadequate configuration management is a leading cause of cost and schedule growth on development programs. When changes are implemented without proper CCB review, the as-built system diverges from documentation, making maintenance, training, and future modifications more expensive. Government audits of configuration management practices can result in formal deficiency findings and increased government oversight.

Example

A defense prime contractor's CCB receives a Class I Engineering Change Proposal requesting a substitute material for a structural bracket after the original material becomes unavailable. The CCB, composed of engineering, contracts, manufacturing, and program management representatives, reviews the ECP for technical risk, cost impact, and schedule impact. After approval, the ECP triggers updates to the technical data package, the test plan, and the production drawing set. All deliverable units produced from the change-effective unit number forward use the new material.

Frequently Asked Questions

What is a Configuration Control Board (CCB) and who sits on it?

The CCB is the formal body responsible for reviewing and approving (or rejecting) proposed configuration changes. Membership typically includes the program manager, chief engineer, manufacturing representative, contracts administrator, and configuration manager. For Class I changes, a government representative may co-chair or approve the CCB decision.

How does configuration management relate to software development on government contracts?

Software CM is governed by the same principles as hardware CM but uses software-specific tools (version control systems, build management tools) and standards (such as IEEE 828). Software builds, versions, and releases must be tracked and controlled. A common pitfall is applying rigorous hardware CM but treating software informally, software changes can affect system functionality just as significantly as hardware changes.

What is a configuration audit and when is it conducted?

Functional Configuration Audits (FCAs) verify that the as-built item meets its performance requirements by examining test results and analysis. Physical Configuration Audits (PCAs) verify that the as-built item matches its technical data package by physically inspecting the item against its drawings and specifications. FCAs and PCAs are typically conducted before First Article acceptance and production releases.

Can configuration management be applied to services contracts?

Yes. Services contracts use CM to control changes to processes, procedures, and work instructions. When a performance standard changes, the CM process ensures the change is documented, communicated to all affected personnel, and implemented consistently. This is particularly important in facilities management, IT services, and logistics support contracts.