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In a product with a BOM and 42 (6x7) variants, seven of the variants require an extra operation (painting) in the routing. What is the preferred way to do this? Can the extra step be added to the routing and only be called for if the variant to be manufactured contains a certain product (paint) or will this force the other 35 variants to go through a "paint-less" paint operation?

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You might look at Steps in the routing, as steps can be defined by product variant.  If that is not doing it properly, you need to create specific BOM for these variants and specific routing.  Maybe consider that these 7 variants get their own product master? 

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