How 5G is Transforming the Manufacturing Landscape - CONNECTING MANUFACTURERS WITH THE FUTURE
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CONNECTING MANUFACTURERS WITH THE FUTURE: How 5G is Transforming the Manufacturing Landscape
2
It is a new day in modern manufacturing. Changing
operational requirements are increasingly demanding data-
intensive technologies. At the same time, the existing wireless
network protocols are not fully suited to deliver everything the
modern manufacturer needs. Increasing deployment of the
fifth generation of cellular wireless technology, colloquially
known as 5G, will empower manufacturers and their workers
to meet this future.
5G will usher in faster speeds, greater throughput and lower
latency. The network specifications also promise greater
reliability, extended battery life for connected devices
and support for massive device connectivity. Not only will
these network characteristics combine to revamp current
manufacturing activities, but 5G will also be a catalyst for
innovation. 5G will empower workers across the factory floor
in myriad ways, helping to support the men and women who
make things in America.
The following paper presents new research exploring how
manufacturers perceive 5G capabilities and their plans to
fully utilize the unique potential of 5G connectivity. 5G is a key
ingredient in defining the next generation of manufacturing in
America. With its help, manufacturers will improve the quality
of products, optimize workflow and deliver new products and
The combinatorial power services to internal constituents and external customers.
of 5G and manufacturing
has broad implications. The combinatorial power of 5G and manufacturing has broad
implications. Nearly all manufacturers believe 5G connectivity
will be important to the overall future of their businesses.
Crucially, the faster 5G technology can be deployed to
manufacturing, the more competitive manufacturers feel they
will be; the vast majority report the speed of 5G deployment
will have a positive impact on their ability to compete globally.
The rate of 5G uptake among manufacturers, and what they
can accomplish with this transformative technology, could
increasingly define the competitive landscape and thus
manufacturing more broadly.
3
Executive Summary
Manufacturers believe 5G connectivity 5G can help manufacturers adapt to
will be important to the overall future of challenges in the aftermath of the
their business. COVID-19 pandemic.
• Nearly all manufacturers (91%) believe 5G • Manufacturers overwhelmingly believe 5G
connectivity will be important to the overall connectivity can help them adapt to challenges
future of their business, with three-fifths (61%) related to COVID-19. Nine in ten manufacturers
indicating it will be “extremely important.” (88%) indicate 5G connectivity will allow engineers
to troubleshoot remotely. An equivalent number
Manufacturers are beginning to test and of manufacturers (87%) also report that remote
implement 5G solutions. visibility and monitoring enabled by 5G will help
• More than half of manufacturers (56%) report them adapt to the COVID-19 crisis.
they will be testing or using 5G in some capacity
within their facilities by the end of 2021. 5G will aid manufacturers with existing
ways of doing business.
• In the long run, most manufacturers are likely to
• Nine in ten manufacturers believe the utilization
implement 5G technologies. Only a very small of 5G in their facilities will help with existing ways
percentage of manufacturers (2%) believe they of doing business (92%) and will further advance
will never implement 5G solutions. existing processes (88%).
Manufacturers believe speed of 5G 5G will drive new processes and create new
deployment is important for global business opportunities for manufacturers.
competitiveness. • The creation of new processes and businesses
• Nine in ten (91%) manufacturers indicate speed is an especially important outcome of 5G
of 5G deployment will have a positive impact deployment. Beyond what manufacturers
on their ability to compete globally, with nearly are currently doing in their facilities, nine in ten
two-thirds (62%) signaling it will have a “strong manufacturers also expect the utilization of 5G to
positive impact.” 5G will help define global lead to the creation of new processes (88%) and
competitiveness in the decade ahead. the creation of new businesses (86%).
91% 56% 91% 88%
of manufacturers of manufacturers of manufacturers of manufacturers
believe 5G report they will be indicate speed of indicate 5G
connectivity will testing or using 5G 5G deployment connectivity will
be important to in some capacity will have a allow engineers
the overall future within their positive impact to troubleshoot
of their business facilities by the on their ability to remotely
end of 2021 compete globally
4
5G will help transform supply chains and and service (56%) and greater flexibility (53%). In
factory operations. addition, two-fifths believe 5G will be advantageous
• Manufacturers expect 5G to have a strong impact as it relates to enhanced safety and security (45%)
on many facets of factory operations. Four-fifths and increased competitiveness (41%), with one-third
of manufacturers indicate 5G technology will be who believe it will provide for shortened lead times
important to inventory tracking (83%), facility (35%) and lower cost (32%).
security (81%) and warehousing and logistics (81%)
within their facilities. Furthermore, three-fourths of • When asked about a set of manufacturing
manufacturers indicate 5G will also be important activities, manufacturers report all are expected to
to inspection (76%) and assembly (76%) activities, become easier with 5G. Notably, reconfiguration of
with seven in ten saying packaging (72%) and production lines, considered to be the most difficult
employee training (71%) efforts will benefit from the manufacturing activity using current technologies,
deployment of 5G to manufacturing. is expected to see the greatest improvement in
terms of “ease” when 5G technology is utilized.
• Manufacturers also report 5G will impact specific Manufacturers also expect the utilization of 5G
applications on the shop floor, including equipment
monitoring and control (89%), safety procedures
that analyze sensor data in real time (87%) and
employee safety (86%). The vast majority of
manufacturers also report that 5G will aid remote
analytics to support real-time decision making
(84%), condition-based remote monitoring for
predictive maintenance (84%), asset tracking (83%)
and preventative maintenance (82%).
5G will drive cost savings for manufacturers.
• Nearly all manufacturers expect to see some level of
cost savings (93%) as a direct impact of connecting
their machines and equipment wirelessly with 5G.
On average, manufacturers anticipate estimated
costs savings of roughly 38%.
5G will increase machine and employee
productivity.
• Nearly all manufacturers expect to see some level of
productivity gains in machines (94%) and workers to drive considerable improvements in “ease”
(93%) from the implementation of 5G. On average, surrounding remote control of equipment,
manufacturers anticipate estimated equipment utilization of augmented reality/virtual reality (AR/
productivity will increase by roughly 42% and VR) applications, utilization of mobile robots and
worker productivity will increase by 41%. autonomous guided vehicles and automation.
5G is expected to improve numerous The number-one driver of 5G adoption
manufacturing activities that rely on network for manufacturers is the ability for quality
connectivity. control monitoring throughout the
• Compared to current connectivity technologies, two- production process.
thirds (65%) of manufacturers surveyed indicate 5G • More than half of manufacturers also report
is superior in terms of increased efficiency, and more increasing machine productivity (53%) will drive
than half feel 5G will provide for improved quality 5G adoption.
5
Why 5G Matters for
Manufacturers
Manufacturers are consistently looking for ways to improve
operational performance and build greater resilience into their
processes. One promising potential is the expanding deployment of 5G
connectivity and the ensuing services and opportunities that will arise from
pervasive and ubiquitous connectivity.
It is vital to recognize that 5G connectivity is fundamentally different
from its predecessors. While the naming convention might suggest that
5G is simply a linear extension of previous cellular networks, 5G is a
significant step beyond 4G. There is a common misconception that 5G
will deliver better and faster mobile broadband but little more. In reality,
each iteration of cellular network technology has unique characteristics
and properties and, as a result, has ushered in entirely new use cases.
This is especially true with 5G. The 2G network delivered massive mobile
voice communication. The 3G network introduced basic mobile broadband
functionality. And the 4G network empowered mobile streaming of graphic-
rich content. Each iteration connected a wider and more diverse swath of
objects and brought exponential increases in mobile traffic data.
5G has unique properties and attributes, which will define its disruptive
characteristics. These include high data rates, higher system capacity,
reduced latency and massive device connectivity. Commercial 5G
deployment will expand network possibilities beyond any of the previous
cellular network technologies. 5G is a technological paradigm shift, not just
5G has unique properties
an extension of existing technology.
and attributes, which
The unique characteristics of 5G will have an outsized influence on will define its disruptive
manufacturing and the industrial economy. High data volumes will enable
characteristics. 5G
augmented and virtual reality to be delivered over mobile networks, usher in
8K video capabilities and replace fixed broadband, meaning more objects is a technological
can be connected in more places. Low latency enables mission-critical paradigm shift, not just
applications, such as remote mining, traffic control, holograms and real-
time factory control. Massive device connectivity will change how and what
an extension of existing
is measured through applications such as smart meters, logistics tracking technology.
and smart biometrics. Reliable and resilient characteristics of the 5G
network will enable driverless vehicles, the ability to control mobile robotics
in real time and wider reliability on drones.
The 5G standard was designed with objectives that are entirely different
from previous cellular networks. 5G removes barriers that exist in
predecessor networks, enabling its ability to deliver new services not
previously possible.
6
What is 5G?
Nearly 50 years ago on a street in midtown Manhattan, Motorola engineer
Martin Cooper made the first cellular call. While the wireless revolution started
with voice communications, each subsequent iteration of the cellular network
has represented a leap forward as wireless networks have accommodated
another defining technological revolution: the rise of the internet. In doing so,
each major wireless generation since that critical phone call has been defined
by ever-improving data capacity and a wider array of services that can be
delivered over the cellular network:
• 1G (1979): voice calls
• 2G (1991): digital voice, text messaging, dial-up data speeds
• 3G (1998): email, pictures, web
• 4G (2009): streaming video
5G represents the fifth major milestone for wireless communications. It ushers
in a host of capabilities that include the following:
SPEED LATENCY CAPACITY
5G networks can peak 5G networks can send 5G networks can capture
at a rate that is about 20 “roundtrip” data (send data from hundreds of
times higher than that data to a destination and thousands of sensors per
of 4G networks, with back) in less than 10 square mile.
even higher throughput milliseconds, a number
possible in the future. that may drop to under five
milliseconds in the future.
RELIABILITY HANDOFF EFFICIENCY
5G networks can 5G networks can Remote sensor devices
reach up to “five seamlessly hand off data applications connected via
nines” (99.999%) to each other even when 5G low power can operate
reliability, making them devices are traveling at for nearly a decade on
an excellent option hundreds of miles per battery power.
for mission-critical hour, ensuring a robust
applications. connection for high-speed
applications.
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5G offers three main types of Mobile Edge Computing). releases created by a governing
communication services or use MEC is designed to improve international body focused
cases: enhanced mobile broadband performance of high-bandwidth, on many technical details
services (eMBB), massive machine- low latency applications (e.g., covering the evolution of cellular
type communication (mMTC) shared augmented reality or cloud- standards. Release 15 defined
and ultra-reliable, low-latency based games). the initial 5G standard in 2019.
communications (URLLC): Releases 16 and 17, focused on
improving efficiency and power
• eMBB improves what we management among many other
normally think of in terms of things, were approved in 2020,
cellular service: fast access and Release 18 is slated to be
to data from devices such approved in 2021.
as smartphones, laptops or
vehicles for applications such • Also, like 4G, it will take some
as streaming video. Initial 5G MEC allows for more processing at time for carriers to make
deployments have focused on the edge, which means reducing the coverage widespread. While
this service. need to move data from machine U.S. carriers have made good
to cloud and back in the process of progress in building out their
• mMTC brings 5G support for performing data-heavy activities. In networks since 2019, we can
low-power devices such as this way, manufacturers can take expect both coverage and
sensors and other intelligent advantage of MEC to reduce the speed to improve in 2021 and
devices that may need to last in latency for certain applications and beyond. Even so, 5G has been
the field or factory for years on can also prioritize mission-critical adopted more rapidly by carriers
a single battery charge. It builds data. Manufacturers will be using around the world than 4G was.
on LTE standards support for MEC to control robots, drones
such devices. and other equipment that will • Telecommunications company
require low-latency, high-reliability, Ericsson estimates 5G coverage
• URLLC is for devices that increased privacy and security, so reached 15% of the global
need very responsive their performance isn’t hindered by population by the end of
data connections (e.g., the roundtrip time it takes data to 2020, up from 5% at the end
communication between two move from machine to cloud. of 2019. Furthermore, they
autonomous cars on a highway estimate this will grow to 60%
seeking to avoid a collision). As we are early in the 5G transition, by 2026, making 5G the fastest
URLLC is supported by 5G NR we can draw some comparisons deployed mobile communication
(New Radio). It can therefore with the early days of the 4G technology in history.1
achieve far greater performance networks we have used extensively
than LTE and is key to realizing for the past decade: • Just as 4G networks require
the full potential of 5G. devices such as smartphones
• Like 4G before it, which got to have 4G capabilities to take
5G is also often associated with faster over the years as the full advantage of the network’s
initiatives that are not an intrinsic standard was improved, 5G is speed, so do 5G networks.
part of the standard, but which are rolling out in stages and will In 2020, almost all major U.S.
highly complementary. One such get faster in the coming years. smartphone makers released
example is MEC (Multi-Access, or Its advances are defined by at least one 5G smartphone.
8
Other device makers also However, it remains focused
released 5G-enabled laptops, on local networking and cannot
tablets, and hotspots. match the range or device
density capacity of 5G.
5G is not the only wireless network
technology that has recently seen • Bluetooth 5.2: The latest version
a major update or statement of of the popular standard linking
support, although the others are smartphones to headphones
focused on much different solutions and other peripherals will see
and applications. They include the improvements in terms of energy
following: consumption and can be used
for short-range precise object
• Wi-Fi 6e: Wi-Fi 6e represented location.
a generational leap in terms of
speed and network congestion • UWB: Like Bluetooth, ultra-
management versus previous wideband can be used for short-
generations. More recently, range precise object location.
however, the technology has Leading smartphone makers are
been extended into a new now integrating UWB into their
spectrum band that offers more smartphones.
capacity than the previous
bands did combined. While this These shorter-range technologies
should result in the best Wi-Fi are highly complementary to 5G
performance we have seen to and should be broadly supported in
date, Wi-Fi can be an alternative smartphones and other devices in
to 5G where 5G isn’t available. the coming years.
9
Banding Together
All cellular networks operate in in reliability and guaranteed quality wave” implementations are limited;
certain parts of the radio wave of service options. they have been deployed mostly in
spectrum. In general, the higher large open spaces such as parks
the frequency number, the faster 5G can also operate in “mid- and football stadiums but can also
the maximum data rate is but the band” frequencies such as 3.5 be effective for factories. The U.S.
shorter the range is. Today, 4G GHz that offer a speed bump when has been early to embrace these
networks operate below 6 GHz. The compared to some of the lower networks, but many carriers around
networks offering the best range frequencies; these have not been the world plan to deploy millimeter-
operate in “low bands” such as 600 as broadly available in the U.S. wave networks in 2021 and beyond.
MHz and 700 MHz frequencies in as in other countries. Mid-band
the United States. spectrum is home to a variety of Overall, 5G will evolve to become
critical operations. Additionally, much faster than 4G. While 4G
5G networks can also operate in the federal government auctioned networks top out at about one
these ranges, but today deliver off several blocks of spectrum in gigabit per second, 5G networks are
only marginally faster connections. these frequencies in 2020 so we expected to reach up to 10 times
This is because it’s been far more should see increased 5G-related that rate. In addition to speed, 5G
effective for carriers to roll out 5G activity in this band, (e.g., by using offers other benefits, including much
using the same core technology a technology called CBRS (Citizens lower latency, the transmission
used for LTE networks. In fact, LTE Broadband Radio Service) intended time between when data is sent
users benefit from the more efficient expressly for private cellular and received on the network, that
use of network capacity enabled by networks). may become as short as a few
5G. Over time, carriers will roll out milliseconds. As a result, 5G will
standalone core networks (5G NR) The most impressive speed gains be a key enabler for manufacturing
that, in addition to offering greater take place above 24 GHz. However, and industrial applications and
speed, will bring tremendous gains the ranges of these “millimeter- innovations.
105G Manufacturing Applications
Manufacturing can often be a dense population of sensors at a
linear process that requires long previously impossible scale. And it
lead times and carries significant will be able to head off problems by
risk of breakdowns and waste. enabling systems that automatically
As they face ever-growing schedule maintenance or order
global demand and ever more replacements for consumables to
aggressive competition, however,
manufacturers apply sophisticated
approaches to monitoring and
improving their operations. This
adaptability is a key tenet of what
is often called Manufacturing 4.0
or Industry 4.0. Factors include
availability of production, which
can be compromised by unplanned
downtime; performance, or ensure there is minimal downtime.
how well equipment is working It paves the way for self-configuring
versus its optimal capacity and manufacturing lines, proactive
production rate; and quality of equipment maintenance determined
output. As the global pandemic by analyzing sensor data and
clearly demonstrated, factories autonomous vehicles that can
must be increasingly flexible, able begin or perhaps one day complete
to be reconfigured with different outbound logistics.
production lines depending on what
can be sudden shifts in demand. Many technologies need to mature
to realize this vision, with key
components taking a leap forward
due to 5G. Behind the “magic” will
be billions of data points developed
into sophisticated data modules,
analyzed for optimal efficiency and
visualized in dynamic ways. While
many of these applications relate
to each other, they also have value
outside of their linked application.
Five of the key applications
5G can help realize the ideal of a are digital twins, the industrial
modular factory where machinery internet of things, extended reality,
can be quickly reconfigured to autonomous vehicles and robotics
optimize production. It not only and safety and security. While parts
stands to improve the richness of these services can be enabled by
of communication among staff, existing cellular technologies, it will
but also keep them safer as it can require 5G connectivity to deliver
facilitate data collection from a them at scale.
11Digital time visibility into their operations,
Twins they can know how their factories are
performing, how their supply chains
are working, where the risks are and
For years, movie and video game ultimately where the opportunities are.
studios have used motion-capture The vision is to have a single view of
technology to create lifelike models enterprise-level risk and opportunities
and to be able to address these
of how actors move. What if that
remotely and autonomously.
kind of sensor-driven modeling could
be applied to an entire organizational Why is 5G needed to
process? That is the foundational accomplish this vision?
idea of a digital twin, a computer For static reports, or other information
model that represents its physical that does not change on a daily or
counterpart so well that it can be hourly basis, Wi-Fi or other connections
used to understand and predict A View from might be sufficient. To have a global,
enterprise-wide view, we need a
changes with how people, products
and processes interact.
Manufacturing: single communication pipe that is
A Conversation with everywhere. That is where the power
of 5G comes in. It’s global, and it can
Digital twins can be used reactively Honeywell’s Chief transport different types of data. It is
or proactively. When used reactively, Commercial Officer not restricted.
Usman Shuja
they can be studied to pinpoint
The next evolution of this is autonomy.
inefficiencies that may be difficult to
5G allows us to make little things in the
detect using only visual observation. buildings, the facilities and in the supply
When used proactively, managers What is Honeywell’s vision chain act like a system of systems. It
can conduct “what-if” scenarios that for 5G? gives us much lower granular level of
can be analyzed without disrupting We believe that every enterprise insights than we can achieve today.
production processes. in the future will need enterprise
performance management For technology to be adopted, the ROI
capabilities. This means there is a has to make sense, and the business
single pane of glass where you can case has to make sense. The power of
see all of the assets, people and AI and 5G and IoT put together is so
processes in one place and you can big that you cannot ignore it. Moreover,
know all of the interdependencies in the early months of COVID-19,
that exist. We believe you should many manufacturers could not even
be able to monitor and operate operate their factories. So, the need
your business from anywhere in the for digitization and 5G is even stronger
world. If you’re a facility manager, for because of COVID-19.
example, you could do that sitting
at a Starbucks, because you have 5G enables continuity and richness
Digital twins usually require large access to all relevant data. You of data so you can make real-time
datasets to be effective. 5G know who is coming into the facility, decisions. Richer and more continuous
what your maintenance needs are, data provide greater visibility. When
networks can not only facilitate
how much energy you’re using you collect machine information from
the transmission of these datasets and when your contracts are being sensors for example, you might be
across vast distances at very high renewed. You have all of that in one collecting it for maintenance. But the
speeds but, with its low-power place, because systems can talk to data can also be extended for different
variants, can enable sensors for each other. applications, and we can use it to
applications that may require far- build different applications. We can
Today companies have very limited keep using data in multiple different
flung sensors in remote locations
visibility, but once they gain real- ways. This is what we call extensibility
such as stretches of roads or fields in
agriculture applications.
12of the dataset. 5G will take this to Industrial Internet of Things
a level previously unavailable to
manufacturers.
How can 5G empower a The Internet of Things refers their location. In the future, however,
system of systems? broadly to the billions of sensor- this may be augmented or replaced
Today there are systems that do not driven devices that will connect to with technologies such as Bluetooth
talk to each other. A fire system is the global network in the coming or UWB, resulting in a stream of real-
separate from a BMS system because years. Many of these will be part time data that can be transferred
they were designed separately, and
of the Industrial Internet of Things
they were installed separately. But
the problem is that is not the way it (IIoT). These device deployments
should be operating. With a system of focus on measuring the operation
systems approach, these could talk of and parameters around many
to each other. They could be context production-related environments.
aware and dependency aware. This will include measuring how
efficiently factory machines are
operating and the environmental
factors that can affect that operation
such as temperature and humidity.
Likewise, IIoT will also lead to energy
savings and more energy-efficient
operations.
IIoT devices can be a critical
If one camera is broken, or is about component in developing a digital
to be broken, then it can call on the twin application, but they can
inventory system, and say, “It looks also have great value for other
like this camera is going to break, and
applications. For example, IIoT
I need to either make a repair or I need
to order a part to fix it.” This is enabled sensors can be used to provide among facilities via 5G. The case
because it is aware of its environment, real-time input to factory-floor for 5G is even greater for outdoor
and it can talk to other systems like workers on the operational health track-and-trace, where technologies
the inventory management system. of machines, helping to ensure such as GPS, 5G and, ultimately,
So, all of these diverse systems can worker safety. They can also report smart roads can deliver real-time
communicate in real time and act like
on longer-term potential challenges, intelligence on variables such as
one system.
such as whether a part needs to be load optimization and handoff
What are some of the most replaced or whether lubricant needs between sites.
promising aspects of 5G for to be ordered to ensure its optimal
manufacturers? operation. IIoT-driven data can even Another example relates to
Latency and coverage are big issues unlock new business opportunities in emergency stop switches.
for IoT. In a lot of manufacturing plants, terms of allowing precise monitoring Historically, these have been
there is no access to connectivity, so of costs for manufacturing-as-a- permanently wired to machines,
you cannot implement IoT solutions. service scenarios. limiting their control to only that
Speed and dependency allow you to
machine. Using 5G, which can be as
go autonomous. Autonomy cannot
happen without 5G. 5G also enables One example of an IIoT-driven reliable and responsive as a wired
supply chain visibility like nothing has application is “track-and-trace.” connection, switches may be able
ever done before. Indoor tracking and tracing of to shut down multiple machines in
assets usually consists of scanning case of a malfunction or accident,
barcodes or RFID tags to determine improving worker safety.
13Extended Reality
Extended reality, or “XR,” represents the set of products that work by putting a smartphone in front of
technologies that runs the gamut from virtual reality— your eyes to advanced systems that cost thousands of
an immersive experience that completely shuts out the dollars and can match the resolution of the human eye.
physical world—to augmented reality, in which digital Newer products offer impressive image quality at less
objects appear and can be manipulated in the real world. than $1,000. In contrast, leading-edge augmented reality
headsets continue to cost thousands of dollars or are in
XR has many horizontal business applications. For limited distribution.
example, several companies have developed meeting
room collaboration applications for geographically For both VR and AR headsets, however, tradeoffs affect
dispersed teams; these include digital versions of price, image quality, how wide a view one can see (field
many of the tools used in in-person meetings, such of view) and, in the case of headsets not tethered to a
as whiteboards and sticky notes. Some even allow PC, battery life. The next few years should see great
the inclusion of two-dimensional PC screen output for strides in these areas.
viewing webpages in a virtual environment. However,
XR has particular value in sectors like construction and An emerging breed of headset connects to a smartphone
manufacturing, where participants can see detailed via a cable, using that device for processing and
connectivity while it is tucked away in a pocket as the
headset handles the display and input. This allows the
headsets to be much lighter, smaller and less expensive.
Even so, many XR applications allow users to participate
with currently available smartphones and tablets,
providing a window into the virtual world, albeit one not
as immersive as the one provided by a headset.
XR is already being used in a range of tasks related
to manufacturing such as training workers via live
interactions or prepared tutorials and troubleshooting
problems remotely. By using augmented reality, this
can occur right next to the parts of a machine that a
technician must service. Headsets can be combined with
biofeedback sensors to determine how effective training
is or how well a trainee responds to stressful situations.
While the compelling 3D graphics of these technologies
get most of the attention, the ability to look up content
from a digital service manual hands-free is also a
great productivity aid facilitated by 5G, particularly
models of complex machinery. Manufacturers can if a technician wishes to search tomes of technical
present data and information about machinery in manuals via voice commands. XR can also play a key
spatially relevant ways, which in turn can aid workers in role in product development, enabling engineers and
maintenance, repair and training. designers to see the effects of changing specifications
without having to build new prototypes and offering a
XR applications are ideally experienced through a level of detailed visualization that can reduce errors in
headset. These have ranged from inexpensive VR manufacturing.
14Autonomous Vehicles and Robotics
While the dream of the self- autonomous vehicle technology at Furthermore, not all autonomous
driving car has been with us for Level 3. But fully autonomous cars vehicles navigate public roads. 5G
decades, the past decade has seen and trucks have clear commercial can also be used to guide robots
enormous progress as a range of applications that can have far- or forklifts through factories using
efforts have leveraged advanced ranging, if sometimes indirect, many of the same core-enabling
imaging sensors, computer vision benefits for manufacturing. For technologies such as advanced
and machine intelligence. These example, autonomous vehicles computer vision destined for
are combining to match or exceed passenger cars.
the judgement and reflexes of
humans. Self-driving cars have 5G will drive next-gen mobile robots.
logged millions of miles. Even in the One of the main requirements for
case where human drivers continue remote-controlled robotics is low
to operate accelerators, steering latency. LTE networks do not deliver
wheels and brakes, 5G can play a latency levels low enough to make
key role. It can not only help with controlling robots at a distance
tools that drivers use to have better feasible. But extremely low latency is
understanding of their environment, one of the defining characteristics of
but also in helping to keep them safe 5G networks. 5G will help automate
and comfortable. dangerous tasks by providing the
ability to control equipment at a
The autonomous vehicle industry has distance in near real time.
identified five levels of autonomous
driving (in addition to a Level 0 that 5G also has the potential to enable
includes no autonomy): advanced automation through
zero-touch approaches. From
• Level 1: Driver Assistance, a forklifts to drones to warehouse
single autonomous system such as shelves themselves, 5G will
cruise control connect autonomous modes of
• Level 2: Partial Automation transportation. These, in turn, will
impact a wide range of facility
• Level 3: Conditional Automation, services. All forms of transportation
in which the vehicle can perform within the future factory could be
most functions, but human connected to the 5G network.
interaction is still required could deliver supplies to factories
and deliver products from factories Manufacturers are increasingly
• Level 4: High Automation, in efficiently and safely. To reach their moving from static configurations
which the vehicle generally handles
full potential, such vehicles will have to more flexible and customized
all functions, but human interaction
to communicate with each other production. 5G will enable
is still an option
and other connected, intelligent manufacturers to respond to real-
• Level 5: Full Automation, in which parts of the transportation grid time upstream and downstream
the vehicle fully handles all driving using technologies referenced conditions and in turn be more
functions without human intervention under the umbrella term “vehicle-to- agile during times of shifting market
Today, some vehicles can operate everything” (V2X). demand and dynamics.
15Safety &
Security
Finally, 5G opens the door to
multiple high-definition video
streams from fixed cameras and
drones (likely navigating via the
5G network as well) to ensure the
security of facilities or monitor for
any signs of disruption or failure,
particularly when paired with a
computer vision system that can
analyze this video and detect
aberrations or dangerous situations.
Emerging imaging sensors can AT&T’s Director of
capture richer details about a scene, AT&T’s Director Digital Transformation
identify materials based on reflection
patterns and even capture video in
of 5G Center for Manufacturing
almost total darkness. These video of Excellence & Operations
feeds can provide proof of what may
be inferred via sensors. Cameras can
Jason Inskeep David LeBlanc
also help ensure compliance with
maximum occupancy laws and to View From Network Carriers:
ensure that personnel are following
safety protocols.
A Conversation with AT&T
What are you seeing as the changes the traditional paradigm
biggest drivers of 5G for around connectivity and return
on investment. 5G is really about
manufacturing? improving product process quality
The need for data and operational
and increasing production velocity,
visibility is growing faster than
which in turn reduces unit costs.
our current means and ability to
Manufacturers are able to produce
connect using traditional methods
parts at a higher quality and at a
for connecting. Manufacturers are
higher velocity.
hitting these major walls where you
can’t just push more of the same
wireless and wired technology to How do you see 5G enabling
enable more devices. 5G brings an the manufacturing workforce,
entirely new way to connect at the and where does automation
exact time manufacturers need new fit in?
ways to connect to bring the next There is a lot of discussion around
generation of services, applications 5G and automation, but 5G
and products. automation isn’t about targeting
labor cost reduction. 5G is more
What’s been the immediate driver about trying to meet demand for
of 5G in many instances is cost. higher-quality requirements and
Obviously, there are technical higher velocity in terms of production
runways that manufacturers are operations. In this way, 5G is
aiming to achieve, but 5G really aligned with what manufacturers are
16trying to accomplish and what the in place and how those processes its integration partners. We are seeing
manufacturing workforce is working work today—and now use that as an a host of creative ways 5G can be
to achieve. opportunity to brainstorm and ideate deployed to deliver new services.
around opportunities to enable those
How should manufacturers processes in different ways, really Are you seeing an
approach 5G adoption? open up the aperture to the art of acceleration of 5G adoption
the possible.
First, manufacturers need to get among manufacturers?
educated on the baseline construct. We have absolutely seen an
Secondly, manufacturers should take Are there things acceleration in the manufacturing
an inventory of the things that are manufacturers should be space toward 5G adoption. In many
connected today. Notice we didn’t thinking about differently as instances, they are taking a hybrid
say, “just focus on those things that they approach 5G as opposed approach to connect new things.
need high bandwidth or need low Manufacturers have already invested
latency.” Manufacturers should start to any of the connectivity
a tremendous amount into their
with looking at what is connected technologies that have current facilities and capabilities.
today because this will help them preceded it? Manufacturers shouldn’t feel like
define opportunities that are unique There’s a learning curve that most they have to rip out and replace
to their business and business manufacturers are going through their existing infrastructure. 5G is
processes. Thirdly, manufacturers right now. Manufacturers are learning about bringing in another means to
should look at the things they never how 5G, and more broadly cellular connect in order to create operational
thought would be possible. in general, is fundamentally different efficiencies. Leverage what you have
than other connectivity solutions. And today and build on that. And as
Here’s just one example of what we manufacturers are learning how to manufacturers employ 5G, they will
mean by thinking about what you think differently. The knowledge set also make those existing connections
never thought was possible. We are for network connectivity capability has more efficient because they are
working with a manufacturer who historically been with OEMs or with not bogging down those historic
has block concrete on the ground the network operators for previous connections with more devices and
of their plant and underneath it they generations of cellular technology. new service requirements. 5G will
have pipes that carry chemicals from help manufacturers to augment their
outside storage facilities into their Moving forward in a 5G world, more of operations and help them achieve
fabrication area. In the past, they the knowledge will need to sit within their digital transformation goals and
did not use temperature sensing on the manufacturer working closely with requirements.
this part of their operations because
they feared the return on investment
would not match the cost of getting
connectivity into those tunnels.
We were able to work with them,
using 5G together with sensors, to
penetrate through the block concrete.
Suddenly, now a battery-powered
sensor can tell them temperature
changes, which can impact their ROI
much greater than they had previously
realized without having to add
connectivity inside the underground
environment. And they hadn’t realized
it because the technology available to
them had limited their thinking about
what was possible.
Manufacturers need to take a catalog
of all of the processes they have
17Private Networks
Private networks have long been applications that require very low spectrum in the 3.5 GHz range
an option for companies and other latency. For the former, deploying that the FCC has designated
organizations seeking to have more LTE networks can be a great way for such networks. John Deere
control and personalization over a to lay the foundation, particularly acquired a CBRS license and
cellular network with early cellular for enhanced mobile broadband will use it to explore streamlining
networks serving voice applications applications in advance of its manufacturing process and
for public safety and railways. These availability of 5G network equipment developing farming applications.
have continued on throughout availability. LTE and 5G are widely It plans to deploy 5G in that
successive cellular generations. expected to coexist on the same spectrum next year. While mid band
However, because of their industrial private networks for at least the applications function well indoors,
capabilities, 5G networks are next five years. the high speeds and extremely
drawing strong interest for private low latency of millimeter-wave
network implementations. networks make them ideal for
factory applications demanding
There are a number of reasons high bandwidth. Already in 2019,
for manufacturers to consider Siemens has set up a private
installing private 5G networks for standalone 5G wireless network in
the factories, plants and facilities. Siemens’ Automotive Showroom
Manufacturers who have a strong and Test center in Nuremberg,
belief in the benefits of 5G and Germany in the 3.7-3.8 GHz band.
see it as a strategic asset that Bosch and Nokia have partnered
provides competitive advantage to deploy a private 5G network
will potentially want to share in or at Bosch’s factory in Stuttgart-
assume capital expenditures to Feuerbach, which also operates in
build out a private 5G network. the 3.7-3.8 GHz band.
Private 5G networks will provide
manufacturers with an ability to One alternative to having a
target 5G deployment to specific completely private 5G network
geographic areas, particularly with private infrastructure is taking
outside of densely populated Indeed, greater support for the advantage of network slicing. In
urban areas. Moreover, private 5G kinds of real-time low latency this scenario, companies partner
networks can provide enhanced performance enabled by 5G SA with a carrier, which can create
privacy, security and control over (standalone) networks continues multiple virtual networks dedicated
network configuration, including to be addressed in the evolving to business applications. Network
options to enhance availability, 5G standard. Further details are slicing can also be complementary
quality of service, reliability expected to be rolled out with the to a private 5G network for
or latency. Release 17 specification due to be companies that want more control
finalized in mid-2022. over wide-area applications where
In general, companies are pursuing it would be logistically or financially
two main kinds of applications on One of several options for building challenging to deploy private
these networks: high-bandwidth private 5G networks in the U.S. is infrastructure. Network slicing can
applications for tasks such as CBRS (Citizens Broadband Radio be implemented under LTE with an
streaming video and real-time Service), a swath of mid band eye toward transitioning to 5G.
18Early Implementations
As 5G networks continue to advance, we’ve seen manufacturer is using large numbers of sensors
pilots on both sides of the Atlantic in implementing monitoring vibration, pressure and temperature and
5G-enabled factories, often in partnership with carriers. using analytics to predict equipment failures. Also,
in the U.K., Ford is working with Vodafone to test
• In Germany, Siemens has partnered with Qualcomm 5G connectivity with welding machines on a private
to deploy a private 5G network at the Siemens network. According to Ford, key components in an
Automotive Showroom and Test Center in electric vehicle require about 1,000 welds that can
Nuremberg. This was the first private 5G standalone generate half a million data points every minute, a
(SA) network in a real industrial environment using good match for 5G’s high-capacity data capture.
the 3.7-3.8GHz band. Since November 2020
Siemens has deployed its own in-house developed • In North Carolina, Corning is working to explore how
private 5G test network and is planning to roll this millimeter-wave 5G can enhance factory automation
out to its own manufacturing locations in Amberg and quality assurance at one of the largest fiber-
and Karlsruhe. In addition, Siemens also plans to optic cable manufacturing facilities in the world.
setup a 5G test network at the Deutsche Messe The companies are testing how 5G can improve the
fairgrounds in Hannover. navigation and functionality of autonomous guided
vehicles. In addition, they are exploring how 5G can
• In Spain, Gestamp, a manufacturer of major auto accelerate data collection, enable near real-time
chassis components, has partnered with Telefonica machine communication, and help wirelessly track
to deploy 5G in a Barcelona factory. The initiative materials with 5G-connected cameras.
has included connecting robotic welding machines
to 5G networks to capture and process data in real • In France, Schneider Electric has partnered with
time and feed it into simulation models generated Orange to trial 5G on an indoor, private network.
by a digital twin of the factory. Gestamp seeks to The goal is to help the convergence of information
improve the flexibility of its facilities in response technology and operational technology. Five indoor
to increasing customization of car models by its 5G antennas have been installed at a Normandy
customers. factory, covering nearly 2,000 square meters of
production space. In addition to working with
• In Texas, AT&T collaborated with Samsung to 5G-enabled tablets and laptops, the factory is
explore ways to use a private millimeter-wave 5G testing use of a 5G-controlled telepresence robot to
network along with LTE and Wi-Fi to train new enable remote visits that can relay high-quality video
workers using mixed reality. Samsung can use and audio while helping to reduce travel costs.
augmented reality (AR) headsets such as Microsoft’s
HoloLens to bring new workers up to speed more • Drishti is working with DENSO, Ford, Nissan and
quickly. Samsung touts the advantage of workers other advanced auto and nonauto manufacturers
being able to navigate a factory floor without losing to deploy cameras across manual assembly lines.
a connection to video training as well as the ability It uses AI to analyze continuous streams of video,
to connect with a remote expert if workers need creating data and insights that are used to improve
help; they can instantly send photos or videos of efficiency and reduce assembly defects. Drishti
what they are seeing since the headset has an moves extraordinarily large volumes of data while
integrated camera. performing AI inferencing in extremely short periods
of time and believes 5G will provide a generational
• In the U.K., Worcester Bosch has deployed 5G to leap in speed and capacity for its plant operations
enable preventative maintenance in real time. The and productivity solutions.
19Perceptions & Reality of 5G
Manufacturing Deployment
We are still in the very early the manufacturers surveyed report portion of their operations. Just
days of 5G deployment, they are already testing or using 5G under two-fifths (37%) estimate they
especially as it relates to in their facilities. Moreover, more than will have at least 25% of production
manufacturers implementing half of manufacturers (56%) report capabilities integrated by the end of
5G-enabled technologies and they will be testing or using 5G in 2021. This research further suggests
solutions. The full extent of 5G some capacity within their facilities that by the end of 2022, more
capabilities will be realized over by the end of 2021. Only a very small than half of manufacturers (56%)
the coming decade as the network percentage (2%) of manufacturers anticipate having at least 25% of their
comes more fully to fruition. But as report they do not expect to production capabilities integrated
this research reveals, manufacturers implement 5G solutions. with 5G capabilities. Regardless of
are already beginning to test 5G in the actual uptake timeline, it is clear
their factories and facilities. At the Manufacturers also have plans to 5G is on the forefront of technology
present time, one-quarter (25%) of implement 5G across a meaningful roadmaps for manufacturers.
Begin
Begin5G5GIntegration
Integrationinto
into Have
Have25%
25%of ofProduction
Production
Anticipated
ExistingTimeline
Existing Operations
Operationsfor 5G Integration2 Capability
CapabilityIntegrated
Integrated
Begin 5G Integration Have 25% of Production
into Existing Operations Capability Integrated
Currently
Currently
Testing/Using
Testing/Using 25%
25%
2021
2021 31%
31% 2021
2021 37%
37%
2022
2022 17%
17% 2022
2022 19%
19%
2023
2023 10%
10% 2023
2023 11%
11%
2024
2024 5%
5% 2024
2024 9%
9%
2025
2025&&Beyond
Beyond 3%
3% 2025
2025&&Beyond
Beyond 12%
12%
Never
Never 2%
2%
Don’t
Don’tKnow
Know 7%
7% Don’t
Don’tKnow
Know 12%
12%
205G Will Help Resolve Current Manufacturing
Challenges Related to Wireless Technologies
In recent years, wireless technologies Another challenge that has inhibited wireless technology adoption
have been a key focus for is interference from existing equipment and infrastructure. Many
manufacturers, yet to date, there manufacturers have legacy facilities, equipment and processes, and
have been several inhibitors that some manufacturers have seen challenges with how existing operations
have curtailed the extent to which combine with wireless technologies. For example, when it comes to
wireless solutions can augment implementing wireless technologies, manufacturers report challenges
production and improve operations. with interference from facility elements (38%), facility barriers (35%),
About half of the manufacturers facility environment (33%), integration with legacy systems, processes
surveyed report cost (51%) is the and equipment (31%) and density of devices (23%).
number-one challenge related to the
implementation of current, existing
or anticipated wireless technologies. Challenges Related to Implementation
Unsurprisingly, manufacturers look of Wireless Technologies3
closely at the return on investment of
wireless solutions, and thus far, that
has limited some of the deployment Cost 51%
of wireless technologies in factories
and plants. Manufacturers will be Ensuring reliability 40%
looking closely at ROI when it comes
to 5G deployment as well. Interference from facility elements (i.e., vehicle cages,
ductwork, machines with electrostatic discharge, etc.) 38%
Dependability of wireless
technologies is another key
Facility barriers (i.e., walls, glass, radio frequency
interference, etc.) 35%
challenge for manufacturers. Some
40% of manufacturers report that
Facility environments (i.e., temperature, humidity,
moisture, shock, vibration, etc.) 33%
ensuring reliability is a key concern
when deciding to implement wireless Legacy systems/processes/equipment 31%
technologies. This is especially true
for indoor environments that are Device density 23%
notorious for radio interference.
As previously noted, one of the
key performance indicators (KPI)
Other 3%
specified by 5G is Ultra Reliable Low None of
Latency Communication (URLLC) the above 7%
service requirements. This translates
into 99.999% reliability and 99.999%
availability. 5G should significantly Many of these challenges can likewise be mitigated by 5G. For example,
help mitigate this challenge for Wi-Fi networks can experience interference in dense settings, and fixed
manufacturers and could allow many wired connections can be difficult to manage across large industrial
manufacturers to implement wireless complexes. 5G is expected to support up to 1 million connected devices
solutions where they had previously per kilometer (0.62 miles), compared to a few thousand devices per
resisted because they could not kilometer with 4G. This will enable manufacturers to deploy wireless
deliver reliable network connections. solutions where a density of connected equipment exists.
215G Will Enable Smart
Factories & Industry 4.0
While connectivity is a key aspect of smart factories, months, or in the absence of data, instinct that might
ultimately it is data that will enable this future. Here, differ from person to person.
too, we see manufacturers face a number of related
challenges. Manufacturers report their biggest In recent years machines have been outfitted with
challenges with respect to facility analytics include sensors that enable manufacturers to turn information
ease of integrating data from multiple sources into data by capturing this information both digitally
(44%), volume of data (40%) and cost (39%). These and continuously. But much of these data still reside
in information silos within the factory. Manufacturers
are followed by speed of systems response (37%),
continue to struggle with turning these data into
integration with legacy systems, processes and
real-time insights that will help them anticipate needs
equipment (37%) and security challenges or concerns
on the shop floor. For example, roughly one in three
(33%). 5G is purpose-built to resolve many of these (33%) manufacturers report unexpected breakdowns
inhibitors to full facility analytics. is their biggest pain point when it comes to real-
time resource tracking. Other pain points related to
Factory machines generate information related to real-time asset tracking include identifying process
monitoring, maintenance and the management of inefficiencies (33%), cost (33%), human error (30%),
production. Until recently, much of this information inventory estimations (28%), elimination of redundant
went uncaptured in the normal course of operations. assets (26%) and identifying asset location (25%).
Historically, much of the monitoring on a shop floor
would be performed by workers as part of their regular 5G will have a particular impact on the industrial and
business. If machines needed repair, they would be manufacturing sector because it will help factory and
taken offline and repaired. Management might look plant operators alleviate some of these pain points.
for ways to improve production outcomes, but much This will be a crucial step in ushering in a new era
of this was done using data from prior weeks and of AI and machine learning techniques that can help
Challenges Related to Manufacturing Facility Analytics4
Ease of integrating data from multiple sources 44%
Volume of data 40%
Cost 39%
Speed of system response 37%
Integration with legacy systems/processes/equipment 37%
Security challenges/concerns 33%
Other 2%
None of
The above 9%
22companies better ascertain real-time knowledge
about their ongoing operations. 5G is also optimized
to facilitate real-time information gathering that can
help automate processes within the manufacturing
environment. In all of these cases, it is about getting the
right data to arrive at the right time and in the right place
so it can influence the right process. Previous networks
focused on data centralization in the cloud, but 5G will
enable greater compute capabilities within the network,
closer to the end user, the end machine and ultimately
the end process.
5G enables manufacturers to apply AI to data in much
faster timeframes by being able to support a high
population of endpoints within a small geographic area.
This will allow for precision analytics, and in the case of
control implementations, precision manufacturing. Better
analytics in a 5G environment will allow manufacturers to
perform tasks at a much more granular and precise level.
Enabling machines to share information and insights
directly with other machines on the shop floor in real time
will allow manufacturers to automate certain activities
and free workers to focus on higher-value tasks.
Challenges Related to Real-Time Asset/Resource Tracking5
Unexpected breakdowns 33%
Identifying process inefficiencies 33%
Cost 33%
Human error 30%
Wrong/maintaining inventory estimations 28%
Eliminating redundant assets 26%
Identifying asset location 25%
Resource wastage 20%
Maintenance issues 20%
Theft occurrences 18%
Underutilization of the workforce 14%
None of the above 8%
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