The best solution I have found to identify mismatched parts is to use the "manual" positioning. I select the parts that SHOULD be identical and then click on "assign position" in lieu of "autoposition". If the parts are NOT identical, then I start matching up the parts that are identical using the same process. Then I assign a different color to the parts that do match and go by process of elimination. Sometimes it's a user input error, sometimes there are empty holes that are in the profile but no bolts on top of holes with bolts.
I dont know why ASD sometimes creates parts that are mismatched. I havent been using ASD long but I have been aggressively trying to learn the program. A month ago I had my basic structure modeled in and have been learning what the program is and is not capable of. I have spent the past week or so trying to perfect my template, BOM and creating shop drawings. This is the way I have learned how to solve this problem so far.
