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I've tried the bringup package approach but this leads to one overly complicated repository. Finding this hard to maintain and making some operational tasks time consuming.

I then moved to separate repositories for different types of configuration parameter; robot specific, deployed site specific, robot hardware version specific etc. Then branches to facilitate switching between sites, specific robots etc. This can work fairly well with little time investment in the setup. Like you mention the main issue is that if you want to update a single value for all branches of a given repo, but this can be mitigated by splitting out robot specific and manufacturing batch specific configurations

Steve's cloud based solution sounds like a much more scalable long term approach.

Interested to see if there are any other methods out there too.