A digital twin-based
system for
cell-based autonomous production consolidation in an
enterprise resource planning (ERP) controlled
discrete manufacturing environment, comprising: a module for generating a digital twin (101) configured to create and maintain a virtual representation of one or more physical production cells including the associated workstations,
workflow structures, material dependencies and capacity constraints; a demand classification and
cell grouping module (102) configured to receive production demand from an ERP
system and classify the demand into
cell-compatible demand clusters based on routing compatibility,
product family attributes, and production cell capacities; a production consolidation engine (103) configured to generate consolidated planned orders at the cell level by aggregating the classified demand clusters and embedding cell-specific production intelligence into ERP planning objects; a real-
time synchronization module (104) configured to collect operational data from
manufacturing systems, including
machine status,
throughput rate,
queue metrics and capacity utilization, and to update the digital twin models accordingly; a deviation detection module (105) configured to compare the real-time operating data with the parameters of the digital twin models to identify deviations that exceed predefined operating thresholds; and an autonomous recalibration engine (106) is configured such that, when a deviation is detected, the results of the
material requirements planning at the level of the
manufacturing cell are selectively regenerated and the production utilization is redistributed to one or more manufacturing plants (107).