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Reconfigurable Manufacturing System (RMS) appeared as a solution to high variation in customer demands allowing manufacturers to satisfy different amount of demands in different period. RMS satisfies demands by rapidly reconfiguring its hardware and software components, in order to quickly adjust its production capacity and functionality within a part family in response to sudden market changes or intrinsic system change depends on the demand of every single period. This reconfiguration process brings a critical issue within the RMS that is called as reconfiguration planning problems (RPP) introduced in this paper. With the rise of digital twin that has been a global issue, many companies or manufacturers are trying to integrate it into their production systems. There is a need of RMS to apply digital twin in order to hopefully improve the effectiveness and efficiency so that RPP can be automatically solved and controlled. The goal of this paper is to address the importance and requirement of the integration of digital twin simulation into RMS by providing comparison study between normal simulation program and digital twin simulation program. A case study is presented for comparison of two simulation models. Plant Simulation 11 is used for a normal simulation model, while Visual Components is used to build a digital twin simulation model.

The reconfigurable manufacturing system (RMS) appears to be eco-friendly while coping with rapidly changing market demands. However, there remains a lack of discussion or research regarding sustainability or environment-friendly functions within RMS. In this study, the reconfiguration planning problem is introduced to represent the core issues within the RMS. Reconfiguration occurs depending on new demands or conditions in the company by reconfiguring machines, such as removing, adding, or changing parts, giving considerable consideration to arrangement of machines, known as configurations in RMS. Therefore, reconfiguration process is always strongly connected to cost, energy consumption, and, more importantly, data management. The complexity of reconfiguration, product variation, and development processes requires tools that are capable of managing multi-disciplinary bill-of-material(BOM) or product data and providing a better collaboration support for data/information tracking while maintaining sustainability. This paper proposes a multi-disciplinary green bill-of-material (MDG-BOM)—an improved Green-BOM concept—with an additional multi-disciplinary feature to minimize emissions and hazardous materials during product development, as well as manage product information across multiple disciplines during the reconfiguration process. A smart spreadsheet for managing MDG-BOM was developed to allow multiple departments to integrate multiple sources of CAD design data and monitor/track changes throughout each step of the process.

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