Whenever I add new variables, they are not automatically added to all my currently open flows for that configuration.
The product is working as designed. Switching between configurations for a flow does not delete the variables from the previous configuration.
CA Agile Requirements Designer (ARD)- Agile Designer
We recommend saving any currently open flows (or closing and reopening), and then new variables will appear in the flow. This is intended behavior, but could cause a big list of variables. Removing unused variables manually is the only solution.