Breaking Down to Rethink the Build Up: Integrating Used Components in Product Configuration

The transition to circular manufacturing challenges Product Lifecycle Management (PLM)<br/>systems, which remain optimized for linear workflows and lack integration of reuse logic. This<br/>study investigates how returned components can be systematically reintegrated into product<br/>configuration to support circularity. Using a Design Science Research (DSR) approach, a<br/>framework and Product Variant Master (PVM) model were developed through inductive coding<br/>of interviews and observations in an industrial pump manufacturing case. The study provides<br/>structured guides to support quality governance and system-level integration of reuse logic,<br/>enabling firms to translate circularity principles into operational and digital configuration<br/>systems. Findings reveal that reuse requires more granular component treatment than current<br/>PLM systems support. Key barriers include fragmented disassembly knowledge and<br/>incomplete component histories. The PVM-based reuse logic enables configuration tools to<br/>incorporate reused components alongside new ones, improving traceability and<br/>operationalizing reuse. The study demonstrates how PLM adaptation and structured knowledge<br/>management (KM) can embed circularity in configuration systems, with Digital Product<br/>Passports (DPPs) serving as a key enabler.