We are a lighting manufacturer and we have hundreds of products with thousands of possible variants.

Using attributes we have a Sales configurator to make quoting these easier and more accurate. Attributes also allow us to configure the correct components on the BOM

For example we have an LED colour temperature attribute with values, 2700K 3000K 4000K 6500K, then Beam Angle attribute with values, 10° 20° 35° 45° plus other attributes. 

Each time a unique combination of these attribute values is selected a new product variant is dynamically created. 

We use MTO, manufacture route so when an SO is confirmed we have MOs created for each sales order line. 

If we have multiple MOs for the same product variant we can merge these so they are assembled as 1 MO and time is recorded on operations as 1. 

The problem comes when we have multiple MOs for very similar but not identical product variants, for example we are making some luminaires with 10° beams some with 20° some with 35° and some with 45°. These will all be assembled together as a batch just at some point in the process different optics will be added. Currently we cannot identify a good way of recording time across these 4 MOs. 

Can anyone offer a solution or any suggestions to try?