Looking for some advice. I've joined a company who builds products that are mostly make-to-order or engineer-to-order. Our products are configurable by the customer - they pick from a list of options.One is length. So (for example) we offer a product with an extruded aluminum body in 2',4',6',8',and 12' length. For this product we'd set up a part file (body) with a configuration for each length. Each length has configurable features - cutouts in different locations. So let's say each length has three configurations, one for each cutout style. So I end up with the following list of configurations:

2' - cutout style A
2' - cutout style B
2' - cutout style C
4' - cutout style A
4' - cutout style B
4' - cutout style C
6' - cutout style A
6' - cutout style B
6' - cutout style C
8' - cutout style A
8' - cutout style B
8' - cutout style C
12' - cutout style A
12' - cutout style B
12' - cutout style C

...15 configurations. Manageable, in my opinion, but then we get custom requests - custom lengths, custom cutouts, or combinations of these. Currently each custom spec is saved as another configuration in the same file, so my 15 configuration file keeps growing and growing, and features get added and suppressed, and I end up with a bloated, confusing mess that keeps getting worse.

Some options I'm considering:

-Set a rule that configurations are saved for standard options only, and that custom specs are saved separately (need to define how and where)

-Save all files individually with each referencing a common part (the extrusion profile) so that changes to that base part propagate to all referencing parts.

Also, I would like to be able to 'see' everything we've manufactured for a particular part, so if we get a custom order I could see if we've built that spec before and reuse if we have. We're not using PDM - will Workgroup PDM allow me to do a where used on the "common" part file and see what's been made from it? Without PDM I don't know of a way to do that.

I'd love to hear how any of you handle something like this - appreciate anything you all have to offer. Thanks!

Brian