Situated in Lewisville, Texas, Ericssonโs USA 5G Smart Factory exemplifies the future of smart manufacturing. By integrating private 5G networks with Industry 4.0 principles, Ericsson has created a state-of-the-art facility that redefines industrial operations.ย With a $150 million investment, this 300,000-square-foot facility stands at the forefront of 5G manufacturing in the United States, creating 500 new jobs and producing Build America, Buy America (BABA)-compliant products.
Dual Private 5G Deployment for Enhanced Connectivity:ย Ericsson introduced two key private 5G solutions early in the evolution of private network technology. One was a scaled-down macro deployment with core integration, while the other, Industry Connect, utilized unlicensed US CBRS spectrum for small-scale setups.Innovative
Solutions Amid Pandemic Challenges: The factoryโs deployment coincided with the COVID-19 pandemic, which posed integration challenges due to restricted global travel. Ericsson utilized millimeter-wave networks, 5G-enabled smartphones, and augmented reality tools to enable remote integration, minimizing dependence on physical travel and ensuring uninterrupted operations.
Overcoming Device Availability Challenges: Initially, the limited availability of millimeter-wave devices prompted Ericsson to collaborate with ecosystem partners to expand compatibility. The recent inclusion of the mid-band spectrum has further aligned the device ecosystem with global standards, enhancing scalability and functionality.
Workforce Agility and Technology Adoption: A critical factor in the factoryโs success was the agility and adaptability of its workforce. Faced with a scarcity of traditional manufacturing expertise, Ericsson shifted its hiring strategy to prioritize candidates with a passion for technology, such as those experienced in building gaming PCs. This approach fostered a team eager to embrace and experiment with new technologies, driving the factoryโs digital transformation.
Continuous Upskilling and Internal Promotions: The factoryโs flexible workforce became a cornerstone of its operations. Most employee attrition resulted from internal promotions to advanced roles, such as repair, maintenance, and automation. This focus on continuous upskilling cultivated a dynamic and resilient team capable of adapting to evolving job roles.
Empowering Innovation Through Industry 4.0 Principles: Leveraging 5Gโs capabilities, the factory embraced Industry 4.0 principles to enhance operations and solve complex challenges. Employees were encouraged to propose innovative solutions, such as AI-powered inspection cameras and smartphones, for efficient data entry. This approach emphasized empowering the workforce with technology to enhance their roles rather than replacing them.
Below are sample use cases that show how 5G has made routine operations and production processes more efficient and reliable.
Autonomous Mobile Robots (AMR): 5G helps autonomous mobile robots (AMRs) receive instructions from fleet managers and move independently. Reliable connectivity gives them more flexibility, improving logistics and workflows while supporting technology development with partners.
AR for Pallet Checks: AR glasses simplify pallet checks during shipping by measuring dimensions accurately and addressing differences in standards like US and European pallets. This reduces manual work, speeds up operations, and encourages creative problem-solving.
AR/VR Based Training: VR and AR improve training by offering hands-on learning experiences. Trainees better understand production processes, helping them transition into specialized roles like final assembly with confidence.
Collaborative Robots and Worker Support: 5G enables smooth teamwork between workers and robots, allowing employees to focus on higher-value tasks. Robots are viewed as helpful tools that boost productivity, creating a workplace where technology is a support, not a replacement.
Range of Applications: Simple to Complex: Simple Applications: Connecting building systems and basic sensors increases efficiency without changing production routines. Complex Applications: In car manufacturing, 5G changes how production steps are carried out, making processes mobile and more efficient but requiring deeper integration.
Private 5G networks are revolutionizing manufacturing by enabling advanced technologies like AI, robotics, and edge computing. These networks deliver several transformative benefits:
Ericsson has consistently led the way in private 5G deployments, driving transformative advancements in smart manufacturing worldwide. By enabling secure, high-speed, and low-latency connectivity, Ericsson empowers manufacturers to optimize processes, harness real-time data, and achieve exceptional levels of operational efficiency.
Improving Efficiency and Reducing Waste: Ericsson is committed to sustainability, integrating it into its operations and products. Private 5G networks, in particular, play a significant role in this commitment. By providing real-time insights into processes, 5G enables better decision-making and reduces waste. Additionally, it supports intelligent energy management, leading to lower consumption and reduced carbon emissions.
Integrating Renewable Energy: In terms of renewable energy integration, 5G enables the monitoring and management of renewable energy sources, such as solar and wind power. It also helps balance power mixes, ensuring a sustainable energy supply chain.
Tracking Carbon Footprints: 5G plays a crucial role in tracking carbon footprints throughout the product lifecycle. From the design phase, where it supports efficient processes and minimizes waste, to the production phase, where it enables real-time monitoring of emissions and energy consumption, and finally to the customer usage phase, where it provides insights into product impact.
Define a Clear Digital Agenda: Start by outlining a digital plan that identifies systems and processes requiring connectivity. Prioritize areas where 5G can address critical challenges, ensuring alignment with backend processes and stakeholder support for digital transformation.
Focus on Simple Use Cases: Begin with straightforward applications like sensor monitoring and autonomous mobile robots (AMRs) in logistics. These initial use cases demonstrate 5G’s value and lay the groundwork for scaling up.
Build a Flexible Data Architecture: Develop a data architecture that can adapt to evolving needs. Use 5G as a platform for experimentation and continuous improvement, keeping the structure adaptable to future growth.
Prepare IT Teams for 5G: Empower IT teams to handle 5G-specific tasks by collaborating with operators and gaining expertise in licensed spectrum and connectivity basics. Gradually build their capabilities to support more advanced operations.
Expand Competency for Advanced Applications: After establishing basic connectivity, progress to complex use cases like real-time automation. Invest in upskilling teams to optimize latency and deeply integrate 5G into production workflows.
Prioritize Security: Capitalize on private 5G’s enhanced security by designing robust network architecture and using tools like Access Point Names (APNs) for data control. Ensure IT teams are equipped to protect sensitive data and maintain operational integrity.
Take a Strategic, Gradual Approach: Adopt a step-by-step strategy, starting small and building expertise over time. As teams gain confidence, transition to advanced 5G applications, enhancing efficiency and driving innovation.
The success of Ericssonโs USA 5G Smart Factory is built on strong collaborations with industry leaders, academia, and government entities. Key deployments across other facilities further highlight the transformative power of private 5G in manufacturing.
At the Smart Factory Innovation Centre in Wolverhampton, UK, Atlas Copco Tools and Industrial Assembly Solutions utilizes Ericssonโs private 5G network to drive Industry 4.0 advancements. The facility emphasizes smart manufacturing, real-time production efficiencies, and flexible assembly processes. Key innovations include the integration of 5G-connected torque tools, transforming traditional manufacturing practices with enhanced mobility and reliability.
This collaboration highlights the power of private 5G in delivering robust, flexible, and data-driven manufacturing solutions. For more information, please visit Atlas Copco Smart Factory Innovation Centre and TeckNexus Coverage of Atlas Copco Deployment.
Toyota Material Handlingโs Columbus, Indiana, facility exemplifies smart manufacturing transformation through a private 5G network designed by Ericsson and STEP. Spanning nearly 200,000 square feet, this deployment optimizes productivity, strengthens worker communication, and enhances operational efficiency.
Ericssonโs collaboration with STEP and key U.S. carriers ensures robust coverage and data security throughout the facility, enabling Toyota Material Handling to realize the full potential of Industry 4.0. More details on the transformation can be explored through Ericsson’s announcement on the Toyota Material Handling transformation and TeckNexus coverage.
