Unlocking smart factory automation: Why private networks are essential?​ 

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The shift towards smart factories has become a critical element in accelerating digital transformation within the manufacturing sector. In this article, we delve into the key capabilities and use cases that private networks enable within these environments.

Overview

With the rapid development of Industry 4.0, the concept of the “smart factory” has become central to modern manufacturing. Smart factories leverage advanced technologies, including Artificial Intelligence (AI), the Internet of Things (IoT), Augmented Reality (AR), and digital twins, to optimise production processes and unlock new levels of operational efficiency. This article examines how private networks underpin these innovations, enabling specific use cases and enhancing new capabilities.

What is a smart factory?

A smart factory is a highly digitalised and connected facility that relies on real-time data, advanced analytics, and intelligent automation to drive decision-making and operational efficiency. Unlike smart manufacturing which encompasses the broader manufacturing ecosystem, it focuses on the operational and technological advancements within a single production facility to achieve enhanced productivity and adaptability. Often referred to as digital or intelligent factories, these environments incorporate various enabling technologies, such as AI, intelligent automation, AR/MR, advanced analytics and industrial IoT, etc.

Operational benefits of private networks

Beyond supporting individual use cases, private networks offer strategic benefits that extend across the smart factory ecosystem. These networks provide a unified, stable, and secure connectivity foundation that allows for comprehensive data collection, analysis, and decision-making across all operations:

  • Enhanced security: In a smart factory, large amounts of sensitive data, proprietary designs, and operational insights are continually exchanged. Private networks enable manufacturers to gain robust control over access and data flow within the facility. They also help provide a secure, closed environment that is isolated from public networks, significantly reducing exposure to external threats and unauthorised access.
  • Greater flexibility and scalability: Private networks can be customised to the unique needs of each manufacturing environment and expanded as operational requirements evolve. As operational demands evolve, manufacturers can scale up their private networks seamlessly, incorporating additional devices, sensors, or equipment without impacting performance or connectivity. This flexibility enables factories to adopt new technologies, such as adding more advanced IoT devices or integrating robotics, without compromising on network performance.
  • Seamless system integration: Private networks enable smooth integration across factory systems, including manufacturing execution systems (MES), warehouse management platforms, and quality control solutions, creating a seamless, data-driven manufacturing environment.

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Key smart factory use cases

Advanced predictive maintenance

Predictive maintenance is a crucial component in reducing unexpected equipment downtime by continuously monitoring the health of machinery through sensors and analytics. Private networks enable real-time data collection and processing from thousands of sensors, allowing AI algorithms to detect patterns and potential failures before they occur. The stability, reliability and low latency provided by private networks ensure that vast amounts of sensor data can be processed instantly, allowing manufacturers to respond quickly to any problems. This proactive approach optimises equipment life cycles, minimises costly interruptions, and keeps production on track in smart factories.

Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs)

AGVs and AMRs play a vital role in transporting materials autonomously across the factory floor. Unlike AGVs, which follow predetermined paths, AMRs use advanced sensors and mapping technology to navigate freely, adapting to changes in real time. Private networks help enable the low-latency, high-reliability connectivity that these robots require to communicate with one another and respond instantly to environmental changes. This seamless, real-time communication enables AMRs to coordinate movements safely, reducing the risk of collisions and ensuring efficient operations within factories.

Connected workers (safety and production)

Private networks enhance worker safety and productivity by supporting connected wearables, sensors, and communication devices on the factory floor. Wearables can monitor environmental hazards, worker health metrics and location data, generating real-time alerts if safety thresholds are breached. Furthermore, private networks enable seamless data exchange, allowing supervisors to monitor safety and production conditions remotely, thereby boosting both worker protection and productivity. The low latency achieved by deploying private networks ensures that safety alerts reach workers instantly, while the high reliability of these networks provides consistent communication and monitoring capabilities across the entire factory floor.

Remotely controlled/operated equipment

In hazardous or hard-to-access areas, remote operation and inspection capabilities allow workers to control and monitor machinery from a safe distance. Private networks make this possible by enabling HD video feeds and precise control commands, supporting real-time remote operation of equipment. The high bandwidth and low latency of private networks ensure that video and control signals are transmitted in real time, allowing operators to manage equipment safely and effectively. This capability not only reduces the need for on-site personnel in risky environments but also increases operational flexibility and responsiveness.

AR/VR for training

AR and VR are transforming training and maintenance on the factory floor by providing immersive, hands-on learning experiences. Private networks offer the low-latency, high-bandwidth connectivity required to support AR/VR applications, ensuring that training simulations and real-time guidance are smooth and responsive. By leveraging private networks, trainees can access step-by-step visual instructions and gain practical experience in a virtual environment, which is particularly valuable for complex or hazardous tasks. This approach enhances training effectiveness, accelerates skill development, and reduces the costs associated with traditional methods, ultimately contributing to a more productive factory workforce.

Example deployments

Verizon: smart factory deployment at Wichita

Verizon partnered with Deloitte to deploy a private 5G network at Deloitte’s Smart Factory in Wichita, Kansas, showcasing how private networks can revolutionise industrial environments. This facility integrates private connectivity with advanced analytics, IoT, and automation technologies, providing a live example of how real-time insights can enhance productivity and streamline operational efficiency.

At the Smart Factory, Verizon’s private network enables critical applications, including autonomous systems like AGVs and AMRs, predictive maintenance powered by real-time data collection, and IoT connectivity that supports extensive data analytics across factory devices. The network’s low-latency, high-reliability connectivity helps enable responsive and secure operations within the facility.

China Unicom: first 5G fully connected factory in Southeast Asia

On 10 May 2024, Midea, AIS, China Unicom, and Huawei jointly launched Southeast Asia’s first 5G fully connected factory at Midea’s Industrial Park in Chonburi, Thailand. This innovative project is a significant milestone for smart manufacturing in the region, setting new standards for efficiency, safety, and automation in complex production processes.

With comprehensive 5G coverage across the Midea Industrial Park, this factory connects every phase of production through 5G-enabled terminals, enabling rapid machine operation and seamless communication between systems. A dedicated 5G private network has been deployed to support the factory’s operational requirements, providing the foundation for intelligent manufacturing applications and linking each production line in real time.

Conclusion

Smart factories represent a paradigm shift in manufacturing, enabling facilities to become highly efficient, adaptable, and data driven. However, achieving the full potential of smart factories requires robust, reliable, and secure connectivity. Private 5G networks, play an essential role in providing this foundation, unlocking the capabilities of AI, AR, IoT, and other advanced technologies which are critical to smart manufacturing.

As manufacturers continue to face challenges such as labour shortages, rising costs, and supply chain disruptions, investment in Industry 4.0 and private networks will be pivotal. With private networks, manufacturers can ensure that their smart factories are equipped to meet current demands and adapt to the evolving needs of the industry, setting a new standard for production efficiency and innovation.

Zoey Yin

Zoey Yin

Zoey Yin

Consultant

Zoey Yin is a Consultant at STL Partners, specialising in edge computing.

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