How Hitachi Rail’s Hagerstown Plant Embraced Smart Manufacturing with 5G

Hitachi Rail’s new facility in Hagerstown, Maryland is more than just a railcar manufacturing plant—it’s a glimpse into the future of digital-first, smart manufacturing. GlobalLogic, in collaboration with Ericsson, has implemented a 5G Private Network at the site. This advanced connectivity backbone supports automation, real-time AI, and intelligent operations across the factory’s 307,000 square feet.

Overcoming Legacy Connectivity Challenges in Industrial Manufacturing

Before this deployment, many industrial environments like Hagerstown relied on a mix of wired and Wi-Fi solutions that lacked the bandwidth, reliability, and low latency required for modern applications like predictive maintenance or digital twins. For a facility aiming to produce up to 20 railcars per month, any disruption or inefficiency directly affects output and quality. Scaling innovation while maintaining worker safety and equipment uptime presented a complex challenge.

Deploying a Secure Private 5G Network for Smart Factory Operations

The answer was a secure and scalable 5G Private Network designed and deployed by GlobalLogic and powered by Ericsson’s technology. The infrastructure offers ultra-low latency, high bandwidth, and end-to-end control, which are critical for powering next-generation industrial use cases.

This connectivity enables:

• Real-time automation
• Remote monitoring
• Seamless IoT integration
• Predictive analytics
  All within a secure, private wireless environment.

Use Cases: How Private 5G Powers AI, IoT, and Predictive Maintenance

Several use cases highlight the impact of this deployment:

• Physical AI: Robot dogs and inspection bots detect defects and support on-site 3D printing of spare parts.
• Digital Twins: High-speed data exchange allows simulation of railcars before production, reducing errors.
• Predictive Maintenance: Real-time data flows help predict and prevent machinery failures, minimizing downtime.
• Automated Quality Control: AI-driven visual inspections improve defect detection rates.
• IoT-enabled Logistics: AGVs and automated systems move materials safely across the floor.

These use cases not only improve efficiency but also enhance worker safety and product quality.

Why GlobalLogic and Ericsson Were Chosen to Power Private 5G

Ericsson provided the robust private 5G infrastructure, while GlobalLogic brought in deep expertise in digital engineering and system integration. As an official Ericsson Private 5G ecosystem partner, GlobalLogic managed full deployment, consulting, integration into operational workflows, and lifecycle management. Their approach blended AI, cloud, and edge solutions for a resilient and scalable deployment.

Key Benefits of Private 5G in Rail Manufacturing

Key outcomes from the deployment include:

• Improved Efficiency: Real-time data supports faster decision-making and lean operations.
• Enhanced Safety: Workers benefit from automated systems and monitoring tools.
• Scalability: The network can evolve with the factory’s future tech stack.
• Sustainability: The 5G solution supports energy optimization and reduced waste.
• Competitive Advantage: Hagerstown sets a new benchmark in rail manufacturing across North America.

Shaping the Future of Manufacturing with Private 5G and Industry 4.0

This deployment reinforces how Private Networks can revolutionize the transportation and manufacturing sectors. By integrating connectivity with intelligent systems, manufacturers can meet the growing demands of digital transformation while enhancing sustainability and resilience.

The Hagerstown plant becomes a model for other industries looking to integrate edge computing, AI, and automation into their production environments.

GlobalLogic’s End-to-End Role in 5G Deployment at Hitachi Rail

GlobalLogic took on the end-to-end role in the project—delivering everything from technical consulting and system design to network lifecycle management. Leveraging their manufacturing and telco expertise, they ensured that the solution fit seamlessly into Hitachi Rail’s industrial workflows.

Ericsson’s Role in Delivering Low-Latency Industrial Connectivity

Ericsson provided the 5G hardware and core software infrastructure to power the network. Their role was instrumental in delivering the high-performance, low-latency characteristics required for industrial automation. The collaboration between Ericsson, GlobalLogic, and Hitachi Rail exemplifies how ecosystem partnerships can accelerate Industry 4.0 outcomes.

Hitachi’s 5G-Connected Factory Is Now Fully Operational

The private 5G network is fully operational at Hitachi Rail’s Hagerstown factory. It is currently supporting key production operations, including predictive maintenance, digital twin simulation, and real-time monitoring.

• Planning & Design: Completed in early 2025
• Deployment & Integration: Mid-2025
• Go-Live: September 2025
  The rapid turnaround from concept to deployment shows the maturity of private 5G ecosystem solutions.

What Industry Leaders Are Saying About the Hagerstown 5G Factory

Joe Pozza, President of North America at Hitachi Rail, emphasized the strategic value of this deployment: “Our new digital factory in Hagerstown is more than just a train manufacturing site – it is a blueprint for the future of rail production worldwide, harnessing the latest AI, robotics, and digital systems to deliver high-quality, smart, and reliable manufacturing. The project exemplifies true One Hitachi, integrating IT, OT, and product capabilities with digital to accelerate the creation of unique value on a global scale. Private 5G connectivity is a game-changer for advanced manufacturing environments. This secure, high-performance connectivity allows us to automate more processes, protect our workforce, and accelerate innovation.”

Alan Minney, Senior Director at Ericsson, added:“To make Industry 4.0 real, manufacturers need secure, high-performance connectivity that is flexible and scalable. This project in Hagerstown shows how private 5G can power everything from predictive maintenance to collaborative robotics, while reducing energy usage and downtime. We are proud to partner with GlobalLogic and Hitachi Rail to demonstrate the impact of 5G on sustainable manufacturing in the United States.”

Sameer Tikoo, GVP at GlobalLogic, said:“GlobalLogic leveraged its extensive cross-industry expertise–spanning telecommunications and manufacturing— along with advanced digital capabilities from semiconductor-level to cloud solutions, and our more than a decade-long partnership with Ericsson to support this ambitious and demanding project fully. As an official Ericsson Private 5G ecosystem partneropens in a new tab, GlobalLogic was responsible for technical and business consulting, full deployment and integration of the private 5G network into the plant’s processes, as well as complete network lifecycle management and end-to-end service delivery.”

Private 5G: The Backbone of the Future of Manufacturing

The deployment of a Private 5G Network at Hitachi Rail’s Hagerstown plant is a showcase of how advanced digital infrastructure can power smarter, safer, and more efficient manufacturing. With partners like GlobalLogic and Ericsson, Hitachi Rail is not just building railcars—it’s building the future of industrial innovation.