GarthMJ

Well that is the first problem, Windows 10 is NOT supported on SCCM 2012. You need to upgrade to Current Branch.

So Having IP Subnet and AD boundary can cause overlapping boundaries which can casuse problems for site assignment, Why cna the AD and IP subnet boundaries at all? Why are you not use IP Ranges only?

Exactly what boundary type are you using IP Ranges only I hope.

Have you confirmed that the Rules are collecting results on a computer by reviewing the log mtrmgr.log? Until you do this step it doesn't matter how old the rules are.

Has it been 30 days since you created those rules? That report will take time to populate.

When did you create your SW metering rules? if the has been under 30 days, don't expect anything useful for this report and even then you will really need to wait for 60+ days.

First off that report doesn't use HW inventory. It use SW inventory. SW inventory is disabled by default as it is useless. https://www.enhansoft.com/sccm-software-inventory/ Instead use the ARP reports to see what is installed on computers.

To answer your questions directly about one or two SQL instances for WSUS. Is that it will cause conflicts between the two WSUS Servers if they share a db. Aka if some deploys an software update (SU) on WSUS, it will get installed on CM clients too (outside of CM control). From the CM standpoint, CM will change that products and classifications existing within WSUS, including declining SU too. Thereby stopping any WSU deployment of that SU.

You need to give more details. Pen drive of exactly data what data? What is the other WSUS server used for, exactly?

This is very important details that was missing from your first post. How exactly are you updating your existing WSUS server now? Why exactly do you not want to use CM to deploy all SU to all computers? aka why have the second WSUS on the internal network at all?

Is the RAID drivers included within WInPE?

This will not be supported and you WILL have problem when you manage WSUS outside of SCCM for non-SCCM computer. There is NO problem having WSUS installed on the CM server with its own clean db.

Start with a Clean WSUS server using full SQL server.

you don't want to use an existing WSUS server. You want a fresh one that is use SQL database not WID.

is there a question? You do know that you don't need a CAS unless you have 150000 computers.