Digital Twin Cooperation System for Automated BOM Change Synchronization
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Solution Overview
Problem
In the manufacturing industry, changes to Bill of Materials (BOM) and Bill of Process (BOP) require manual data feedback to ERP and MES systems, as well as updates to digital twins, consuming significant man-hours.
Innovation Solution
A digital twin cooperation method that automates data conversion, change detection, and model updates using master data, allowing for automatic data synchronization between business systems and digital twins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual data feedback is performed for ERP and MES systems when BOM/BOP is changed, then data accuracy is maintained, but the number of man-hours required increases significantly
Solution Approach 1:
The patent establishes master data in advance that defines the relationships between BOM/BOP items and their corresponding ERP/MES data. When changes occur, the system automatically matches changes against this pre-defined master data, eliminating the need for manual data feedback while maintaining accuracy through predefined validation rules.
Solution Approach 2:
The patent implements an automatic feedback mechanism where change detection triggers automated data synchronization with ERP and MES systems. The system detects BOM/BOP changes, retrieves corresponding data using master data, and automatically updates the digital twin and connected systems, replacing manual feedback processes.
2Stability of the object's composition
If manual association of MES/ERP data is performed when BOM/BOP is changed, then data consistency is ensured, but construction time of digital twin increases
Solution Approach 1:
The patent enables the digital twin construction process to be self-updating by automatically detecting BOM/BOP changes and retrieving corresponding MES/ERP data through master data. The system self-corrects and self-updates without human intervention, maintaining data consistency while dramatically reducing construction time.
Solution Approach 2:
The patent introduces master data as an intermediary layer between BOM/BOP changes and the digital twin construction process. This master data serves as a translation layer that automatically maps changes to the appropriate MES/ERP data, eliminating manual association work while ensuring data consistency through predefined relationships.
3Loss of information
If comprehensive data feedback is performed for all BOM/BOP changes, then complete traceability is achieved, but system complexity increases
Solution Approach 1:
The patent segments the data feedback process into manageable components: master data management, change detection, data retrieval, and automatic update. Each component handles a specific aspect of the feedback process, reducing overall system complexity while maintaining complete traceability through structured data flow.
Data Source
AI summary
The number of man-hours is reduced for constructing a digital twin with a digital twin cooperation system that causes a business system related to production including product manufacturing to cooperate with a digital twin for simulating the production based on transaction data and model data. The result data related to the production acquired from the business system is converted into the transaction data using the master data and inputting the transaction data into the digital twin. Included are a change detection step of detecting a change in manufacturing information related to the product manufacturing that the business system has; a determination step of determining whether the change is absorbable in the master data based on an existing record of the master data; and an update step of updating the master data or the model data based on the change according to a determination result of the determination step.