Developing reuse logic into product configuration: the operational approach for circularity

Purpose The transition to circular manufacturing challenges product lifecycle management (PLM) systems, which remain optimized for linear workflows and lack integration of reuse logic. This study investigates how returned components can be systematically reintegrated into product configuration to support circularity. Design/methodology/approach Using a design science research approach, a framework and product variant master (PVM) model were developed through inductive coding of interviews and observations in an industrial pump manufacturing case. The study provides structured guides to support quality governance and system-level integration of reuse logic, enabling firms to translate circularity principles into operational configuration systems. Findings Findings reveal that reuse requires more granular component treatment than current PLM systems support. Key barriers include fragmented disassembly knowledge and incomplete component histories. Originality/value The PVM-based reuse logic enables configuration tools to incorporate reused components alongside new ones, improving traceability and operationalizing reuse, with digital product passports (DPPs) serving as a key facilitator of tacit knowledge management (KM).