Understand how use cases can be layered to provide an overall business case for deployment of advanced networks, or how to get additional value for a deployment when you already have one.

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What is the problem to be solved?

Modern factories and manufacturing sites face many data communication challenges that can affect operational efficiency and hinder the adoption of advanced technologies. Traditional wired networks, while offering reliability, present significant limitations in terms of flexibility and cost. The necessity for physical connections means that expanding or reconfiguring networks can be expensive and time-consuming, with cable installation making up a substantial portion of the total connectivity deployment cost.

This lack of agility can be a major drawback in dynamic manufacturing environments where production layouts and equipment configurations may need to be adjusted frequently. Advanced networks, including private 5G, provide a potential solution to this, however their cost means that they are often not justifiable investments for any specific challenge. One approach is to layer individual applications to build an overall business case for investment in networks, and this use case aims to identify several ways to do this. Alternatively, if you already have an advanced network deployed, these use cases can be thought of as ‘value-adders’ that allow you to gain additional returns from your investment.

Wireless communication within factories, predominantly relying on Wi-Fi, throws-up several hurdles.
Manufacturing floors are often covered with machinery and materials that generate wireless signal disrupting interference, and this combined with large metal structures and concrete walls often leads to lower quality communications including data loss.

The increasing density of wireless devices, such as sensors and automated equipment operating simultaneously can also lead to network congestion, resulting in delays and reduced throughput. For critical applications like real-time monitoring and control systems, the reliability and latency of Wi-Fi can be problematic compared to wired alternatives. Security is another concern with traditional Wi-Fi networks due to the shared and unlicensed nature of their spectruym, making them potentially vulnerable to unauthorized access and cyber threats. 

If not properly secured they can be vulnerable to interception and hacking, posing a significant risk to data security. Many industrial facilities still operate on legacy systems that were not designed with cybersecurity in mind and are difficult to update, adding further risk due to the growing convergence of IT and OT networks.

What is the solution to the problem?

Private 5G networks offer a convenient solution to address these various challenges in manufacturing. They offer a range of functionality that can be implemented as individual solutions but also combine to provide a set of features that are extremely flexible. These include:

  • Enhanced Mobile Broadband (eMBB) for high data rates, enabling bandwidth-intensive applications such as high-resolution video streaming for quality control and Augmented Reality/Virtual Reality (AR/VR) for training and remote assistance.
  • Ultra-Reliable and Low Latency Communication (URLLC), which is crucial for real-time applications like the control of autonomous mobile robots (AMRs) and automated guided vehicles (AGVs), ensuring precise and synchronized operations.
  • Massive Machine-Type Communication (mMTC), allowing for the connection of a vast number of low-power IoT devices and sensors, essential for comprehensive data collection across the factory floor.
  • Use of dedicated licensed spectrum, providing a more controlled and predictable network environment. This reduces the risk of interference and ensures more reliable communication, particularly critical for mission-sensitive industrial applications.
  • Network Slicing, which allows manufacturers to create isolated virtual networks with specific performance characteristics tailored to different use cases
  • Seamless mobility and robust handovers, ensuring uninterrupted connectivity for moving assets and people across a manufacturing facility
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All together these capabilities enable a host of ‘value-adders’ for a 5G network, these include:

  • Temporary connectivity requirements, private 5G provides high flexibility, enabling companies to rapidly deploy and redeploy network capabilities as production needs change. This agility is particularly valuable for accommodating temporary production lines, equipment testing, or specific short-term projects without the significant cost and time associated with installing or reconfiguring wired infrastructure.
  • Ensuring a reliable signal for assets in motion, such as AGVs and AMRs. This is critical for efficient logistics and automation. 5G delivers robust handovers, preventing unpredictable latency jumps and enabling mobile assets to operate reliably at higher speeds. The ultra-low latency characteristic of 5G is also essential for the real-time control and navigation of these robots, allowing them to avoid collisions and execute tasks with precision.
  • Tracking of tools or equipment can be significantly improved. By connecting sensors and tags to the network, manufacturers gain real-time visibility into the location and status of their assets. This enhanced equipment management reduces loss or misplacement, minimizing wasted time caused by searching for missing tools, and improves overall operational efficiency.
  • For building management services, an advanced network can integrate various systems and sensors, such as HVAC, lighting, and security systems. This integration allows for tracking and optimizing energy usage, enhanced security monitoring, and improved operational efficiency of the entire factory.
  • The potential for drones in manufacturing environments is unlocked by the high bandwidth and low latency of 5G.  Drones can operate beyond line of sight, enabling applications like remote inspections of equipment and infrastructure in hazardous or hard-to-reach areas, site monitoring for security, and even inventory management within warehouses. The ability to transmit high-resolution video and sensor data in real-time is crucial for these applications, while low latency ensures responsive control of the drones.
  • Replacing corporate WiFi may also be viable once you have a network deployed. It provides superior reliability, security, coverage, and capacity compared to traditional Wi-Fi in industrial settings, handling a larger number of connected devices with consistent performance and offers enhanced security features like SIM-based authentication and end-to-end encryption, making it a robust foundation for digital transformation of the back-office as well as the shop floor.
  • The mMTC capabilities of 5G are highly suited for gathering data from facilities sensors. They enable the connection of a vast network of sensors throughout the facility, allowing for real-time monitoring of machinery performance, environmental conditions, and production processes. This data is invaluable for predictive maintenance, quality control, and overall process optimization.
  • Connecting remote sites via hybrid public/private networks is a solution for manufacturers with geographically dispersed operations. A private 5G network can handle critical on-site operations at each remote location, while the public 5G network extends connectivity for remote monitoring, management, and data exchange. This hybrid approach balances the need for local control and security with the benefits of wider area connectivity.

Commercial model (Business Case)

The business case for deploying a 5G network across a manufacturing site can be difficult to define, but by combining several of the use cases outlined in the previous section it may be possible to justify the overall investment. All together these enable a few measurable improvements that can be assessed as part of the business case:

  • Increased efficiency and productivity are realized through real-time data collection, advanced automation, and reliable communication, leading to optimized production processes, reduced downtime, and streamlined workflows.
  • Cost savings can be achieved through predictive maintenance enabled by continuous monitoring, optimized energy consumption facilitated by smart building management, improved resource allocation through better asset tracking, and lower installation costs compared to extensive wired infrastructure.
  • Enhanced security can be a major driver for certain types of organization, with private 5G offering superior protection for sensitive data.
  • The enhanced flexibility and scalability of private 5G allow manufacturers to adapt quickly to changing production needs and seamlessly support a growing number of connected devices. In addition, this adaptability significantly improves the capacity of an organization to adopt other advanced technologies in the future as they become available like AR/VR for training and remote assistance, AI-driven robotics for automation, and sophisticated analytics for process optimization.
  • Streamlined supply chain management is facilitated by real-time visibility into inventory, shipment statuses, and logistical operations. 
  • Worker safety can also be improved through the tracking of movements, detection of hazardous conditions via sensors, and enabling remote monitoring in dangerous environments.

 

Benefits

When combined into an overall picture, the individual benefits that 5G brings to each use case highlights the technical advantages it has over other possible solutions. Simply put, it is the USB-C of wireless connectivity – a standard that can be used for a range of scenarios that can’t be matched by any single other technology.

For the real-time control of moving assets like AGVs and AMRs, the low latency provided by 5G is essential for precise navigation, preventing collisions and ensuring efficient material handling. Drone-based inspections benefit from the high bandwidth of 5G, which enables the real-time streaming of high-resolution video and sensor data, allowing for detailed remote assessments of equipment and infrastructure.

The vast amounts of sensitive data collected from facilities sensors are protected by the enhanced security features of 5G, including robust encryption and secure transmission channels. For temporary setups, it offers reliable connectivity that can be deployed quickly and easily, adapting to fluctuating production needs. The ability to support a high density of devices is crucial for connecting the thousands of IoT sensors, wearables, and other equipment prevalent in modern smart factories. Seamless mobility and handovers ensure uninterrupted connectivity for workers and mobile equipment as they move throughout the factory floor. 

Finally, network slicing allows manufacturers to prioritize critical traffic by allocating dedicated network resources to mission-critical applications, ensuring their optimal performance.

Real-world deployments offer insights into the successful application of private 5G networks in manufacturing and similar environments and the benefits they can bring. In automotive manufacturing, 5G has been implemented for real-time monitoring of quality and machine performance, leading to improvements in production efficiency.  The logistics and warehousing sectors have also seen successful deployments of private 5G for automating operations with AGVs and AMRs, improving real-time inventory management, and enhancing overall operational efficiency. Port operations, with their demanding environments and need for efficient material handling, have leveraged private 5G to automate ship-to-shore cranes and autonomous ground vehicles, resulting in improved loading and unloading accuracy. These examples underscore the diverse applications and tangible benefits of advanced networks in enhancing manufacturing and industrial operations.

Lessons Learnt 

Planning and implementing a private 5G network in a manufacturing setting requires careful consideration of best practices and potential issues. Make sure that you DO:

  • Understand the available options with respect to spectrum allocation, including licensed, shared, and unlicensed spectrum, and choose the most suitable one(s) based on your needs and OfCom’s regulations.
  • Perform site surveys to ensure an effective network design.
  • Ensure strategic placement of network infrastructure, such as small cells and antennas, to enable optimal coverage and capacity, and allow for future scaling and potential use of features such as location tracking.
  • Carefully plan integration with existing infrastructure to ensure interoperability between the new network and existing IT and OT systems, including legacy equipment and existing protocols.
  • Recognize that a successful deployment requires the involvement of skilled professionals, and you will need to train your team or get in outside help.
  • Carefully manage costs: as with any project ensuring robust requirements and then sticking to them is essential to avoid overruns.  As part of this, make sure you fully explore both the Op-Ex and Cap-Ex costs of the solution you’ve chosen.
  • Look to see if funding from local or central government is available to help you trial advanced technologies such as 5G

By comparison, try to make sure you don’t:

  • End up with signal coverage gaps and other issues caused by not doing a thorough enough initial site survey
  • Deploy older generation hardware that lacks the latest features and security patches
  • Overlook potential sources of signal interference that can impact network performance
  • Perform inadequate security planning that leaves the network vulnerable to threats

Go into the deployment with a lack of clear goals, which can lead to misaligned investments and unrealized benefits.

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