The Different Meanings of "Configuration"
Configuration means different things to different people: variant selection, baseline management, or software parameters. Here is how to tell them apart.
Glossary
Variant Management
Branching
n. (ˈbran-chiŋ)
Definition
Branching creates parallel product variants as independent development paths, without a shared 150% BOM master structure. Learn its benefits and trade-offs.
Branching in variant management refers to the process of creating parallel variants of a product, software, or system as independent development paths. Each branch represents a distinct variant that can be modified without affecting the others.
How branching works
Branching begins by creating a copy or fork of a base configuration. This forked version is then maintained and developed independently — specific features, market adaptations, or customer-specific modifications are applied to the branch without touching the original.
Branches can later be merged back into a shared base (if the changes are compatible) or maintained permanently as separate variants. In practice, permanent branches are common in mechanical engineering, while temporary branches with reintegration are more common in software development.
In contrast to subtractive configuration Subtractive Configuration (səb-ˈtrak-tiv kən-ˌfi-gyə-ˈrā-shən) n. Subtractive configuration starts from a 150% BOM containing all possible options and removes components not needed for a specific variant. Common in automotive and ERP. — where all variants are derived from a single 150% BOM 150% BOM (ˌwən-ˌfif-tē pər-ˈsent ˌbil əv mə-ˈtir-ē-əlz) n. A 150% BOM lists all possible components across all product variants, serving as the master structure for subtractive configuration in variant management. — branching does not require a shared master structure. Each branch is self-contained. This independence is both the main advantage and the main challenge of branching.
Benefits of branching
- Parallel development — Teams can work on multiple variants simultaneously without interfering with each other.
- Risk isolation — Experimental changes or customer-specific adaptations are contained within the branch and cannot affect other variants.
- Customization — Branching allows deep, structural customization that would be difficult to express as a rule within a shared 150% BOM.
Challenges
The independence that makes branching attractive also creates ongoing costs:
- Complexity growth — As the number of branches increases, tracking what changed where becomes increasingly difficult.
- Merging conflicts — If two branches diverge significantly, reintegrating them requires careful conflict resolution. In mechanical engineering, this can mean re-engineering interfaces.
- Maintenance burden — Each branch requires separate attention. Defect fixes, regulatory updates, or component changes must be applied to every affected branch individually.
This is why organizations managing large product portfolios often look for alternatives to branching — such as a shared 150% BOM with configuration rules — that allow variant diversity without duplicating the entire engineering model.
Frequently asked questions
When is branching the right approach in variant management?
Branching works best when variants are structurally different enough that they cannot be derived from a shared master model, or when regulatory, customer, or market requirements make independent development tracks necessary. For smaller numbers of variants with manageable differences, a subtractive configuration Subtractive Configuration (səb-ˈtrak-tiv kən-ˌfi-gyə-ˈrā-shən) n. Subtractive configuration starts from a 150% BOM containing all possible options and removes components not needed for a specific variant. Common in automotive and ERP. approach based on a shared 150% BOM 150% BOM (ˌwən-ˌfif-tē pər-ˈsent ˌbil əv mə-ˈtir-ē-əlz) n. A 150% BOM lists all possible components across all product variants, serving as the master structure for subtractive configuration in variant management. is typically more efficient.
What is the difference between branching and subtractive configuration?
Subtractive configuration derives all variants from a single shared master structure (the 150% BOM) by removing components not needed for each variant. Branching creates separate, independent copies of the product model for each variant. Branching avoids the overhead of maintaining a 150% BOM but trades it for the overhead of maintaining multiple parallel product structures.