This paper conducts a systematic literature review about the management of rule-based product-portfolios with high variance. This type of portfolio is particularly distinctive in the chosen use case of the German automotive industry since it satisfies the requirements of mass customization and modularization. However, the research field of variant- and complexity management is manifold and multidimensional. This paper systematically searches the databases Scopus and Web of Science using the PRISMA method and briefly summarizes the main contributions and comparing them by elaborated topics.

This study explores challenges in decision-making for product design due to insufficient cost transparency because of product variety across the value chain. Utilizing a literature review and a case study on a company, it delves into issues such as value chain consideration, product family assessment, linking effects to specific product levels, and converting measured effects. Highlighting the critical need to address these challenges for decision-making. Future research should focus on a comprehensive costing framework, explore effect interdependencies, and expand the value chain analysis.

Addressing VUCA challenges in product development, the Human-Centred Analysis of External Variety (HAV) method is introduced. Focusing on the early stages of new product development, HAV provides a structured approach, reducing uncertainty through quick market analysis, customer engagement, and goal setting. HAV is illustrated using a cargo bike product family case study and emphasizes its role in aligning human-centred methods with project goals. The first steps of the HAV method are presented, but also the need for further action towards a validated and elaborated method is discussed.

MBSE and SysML are increasingly finding their applications in industry as well as in academia. The reuse of the information described in SysML models depends, among others, on the modelling methods, management of dependencies between elements and on the needed remodelling effort. In this paper, a modelling method is presented that address the reuse of SysML models and descriptions as well as reuse of model variants in SysML. A case example is presented to explain the modelling methods and the gained experience is summarised in the form of general recommendations for further use.

There are various strategies to control complexity and variety growth in ETO businesses. Such portfolio rationalization initiatives sometimes stall. This paper elaborates on the challenges that cause this. Challenges described in literature and challenges seen in five different industry cases are consolidated. The challenges are combined into groups and presented in the ADKAR change management model. The authors intend this list to be used for guidance In industry and expect the collection to be extended with future industry cases and challenges.

Modular product structuring has been proven an effective way to satisfy a high sales variety with low internal product and process complexity but is usually carried out on existing structures. To support the modular new product development, this contribution shows the initial structuring of integrated product and assembly structures based on a variance-oriented product structure. With help of a perspective-based modularization approach, consolidating the product life phases of procurement, assembly and sales, modular product and process structures are developed within an industry case study.

One challenge in product development is the megatrend of product individualization in the automotive supplier industry. Requirements for a variant by the customer may differ from those by the provider wherefore conflicting goals can arise. To cope with variant requests in the quotation phase systematically, a method to evaluate variants is necessary. Based on evaluation criteria the requirements from the stakeholders are valued. While evaluating, an already criterion can have an impact on assessing the remaining criteria. For this reason, the present investigation emphases the interdependencies between the evaluation criteria in industrial practice representing interdependencies within goals, requirements and boundary conditions in an early stage of product development. Analysing decisive factors supports to identify subsequent activities in the development process of a variant. Experts of an international automotive supplier developed impact matrices and a scenario technique tool is used to interpret the matrices. In context of the model of PGE - Product Generation Engineering, findings derive to ensure a comprehensive basis for decision-making concerning a variant-request.