To associate them
#To associate them notnot needed:
- visibilty = not show inidividually
- stock = in stock
- price = also set
- status = enable
needed:
- attribute set = the same as configurable product
to create a config
Beside this you need to make sure, that the attributes you want to be configurable are NOT system, "Global", input type "Dropdown" and "allowed for configurables"
to show them in frontend
Only the simple ones which are in stock and enabled are shown in frontend, might be an indexing issue?