Can not create new representations in an assembly.

I have an assembly that I want to save in two configurations / representations:

  • As manufactured
  • For packing

There are some additional components that I want in the packing config that I will suppress in the as manufactured config.  There are no representations in the assembly, just the physical product.  When I try to create a representation, I get the error:

"The configuration named "abc" already exists for the compnents listed below.  [assembly file name]"

What is going on?