The distinctive benefits of 5G technology are influencing several industries and shall soon transform the digital world. The increased bandwidth, low latency, and security features of 5G technology can drive vast connectivity for machines. High-speed communication can enable reliable automation of the manufacturing units by using IoT and AI technologies. The 5G-based manufacturing will become more flexible and productive.
Industry 4.0 emphasizes the introduction of AI, IoT, automation, robotics, and big data in the manufacturing industry to build efficient and autonomous production units. 5G network offers an exceptional opportunity for the manufacturers to develop smart factories through Turnkey PCB assembly where the device will be fully manufactured in one plant. This will allow higher flexibility, reduced cost, and quicker lead times for production.
5G Features enabling Industrial Automation:
- Excellent Communication speed
The 5G communication can go up to 20Gbps at the highest speed and around 100Mbps at an average data rate with a very low latency of about 1ms. This feature ensures quick and reliable wireless communication in the manufacturing plant.
- Ability to connect numerous devices
Multiple IoT devices can be connected over the internet today. With more sensors on the shop floor, the quality of production can be continuously monitored and controlled. 5G supports connecting many such IoT sensors in the production unit.
- Ensures data security and reliability
5G communication supports local networks for industrial applications and also ensures data security. This is a huge advantage in enabling real-time monitoring of the manufacturing process.
5G in building Smart Factories:
The 5G speed and bandwidth enables immediate transfer of data on the shop floor, resulting in live monitoring of the overall PCB assembly process. The instant reports can be used by the manufacturers to identify the problem areas and suggest corrections if required. A supply chain driven by 5G speed can track all the parts and materials of the manufacturing unit, monitor the assembly setup and equipment for improved uptime, and can reduce material wastage significantly. The 5G wireless network can replace the physical cable connections on the assembly floor and improve the agility of the manufacturing unit to a great extent.
Remote video assistance can be used by industry experts to upskill the assembly-line staff. Multiple sensors placed throughout the assembly line can reduce the need for manual intervention in a hazardous work environment. Also, the monitoring system working at 5G speed can rapidly shut down defective units in case of emergencies. Using AR for troubleshooting assembly line issues can save production time considerably.
5G network is more reliable when compared to any other wi-fi connection. Industrial automation depends on the transfer of a huge amount of data on the internet and analyzing the data remotely. Manufacturers can implement industrial automation successfully using 5G technology as the data collected is accurate, reliable, and cannot be accessed by any unauthorized operator.
The manufacturing industry can be restructured through the path-breaking benefits offered by the 5G technology. Advanced predictive maintenance (using massive data collected by dozens of IoT devices) is possible due to the vast device density and reliability of the 5G network. 5G supported facilities like remote robot control, automated guided vehicle, and drone inspections can increase productivity, reduce manufacturing costs and improve the health and safety of the manufacturing units.
5G Use Cases:
- Improved Supply Chain
The ability to track and coordinate the incoming material, and configure the assembly lines accordingly can immensely improve the supply chain efficiency. 5G provides a real-time tracker of all the materials and synchronizes the manufacturing activities to enhance the production yield.
For example, Siemens Energy has emphasized the importance of digitization by introducing 5G networks, IoT sensors, advanced analytics, and intelligent cybersecurity in its power grids. The grids are driven by 5G intelligent systems that are capable of running cost-effective and sustainable power transmissions. In a survey conducted by Siemens Energy, there were concerns about cyber security in the IoT network of smart energy infrastructure. So, they introduced AI-based security solutions for improved supply chain safety that can identify threats in the early stages.
Automated Guided Vehicles (AGV) used for material movement are usually connected using wifi networks. There may be interference in their communication due to heavy equipment or magnetic fields on the shop floor. Hitachi, a tech firm has collaborated with telecom service providers to leverage the 5G features in building a private network inside its manufacturing facility. This has increased the coverage for connected devices and improved the data throughput. Also, robots used for material movement can communicate instantaneously due to the low latency of 5G connectivity in smart factories.
- Process automation
5G has enabled networking capabilities among various assembly apparatus. This allows automating various repetitive tasks by using IoT sensors, AI-enabled vision cameras, and industrial robots. 5G powered vision cameras in the assembly line can assist floor managers in evaluating the product quality remotely.
For instance, Siemens Transformers Mexico has set up a remote monitoring system with twelve cameras in their factory. The cameras provide a high-quality video, replacing the need for an onsite visit of customers to witness the Factory Acceptance Test (FAT) of their products. This saves time, money, and resources for their customers.
As another example, MTU Aero engines introduced 5G-enabled production technology to create blade-integrated disks used in jet engines. The automated factory helped in reducing the process design time by 75%.
- Equipment maintenance
Low-latency wireless communication allows uninterrupted machine monitoring in the workshop. IoT sensors can quickly detect any problem in the equipment and also indicate routine maintenance updates. The data collected can be used for better management of the inventory.
In one of the cases, 5G enabled connectivity empowered the telecom company, Ericsson to experiment with augmented reality (AR) to repair electronic boards without any need for reference documents.
HIROTEC, an automobile parts manufacturer integrated 5G-based edge analytics technology in its manufacturing process to foresee and avoid failures in its critical systems. This eliminated the need for manual inspections. Analytics can predict equipment breakdown in advance and can reduce the process downtime significantly.
- Additive manufacturing
3D printing has a significant impact on spare parts management in the manufacturing industry. 5G can enable the networking of different standalone 3D printing facilities. This allows remote monitoring and control of 3D printing processes. Spare parts can be created on-demand using 3D printing, which can boost the effective utilization of spare parts and reduce component wastages.
Whirlpool, a multi-national home appliance manufacturer has used 3D printing technology to offer spare parts to its customers on an order basis. This has helped in mitigating parts obsolescence issues and managing component shortages effectively.
GE has highlighted the advantages of 5G-based additive manufacturing in rapid prototyping and in creating complex designs at low-cost and reduced lead time.
Conclusion:
Going forward the flexibility, ultra-low latency, and reduced device costs can drive ‘Manufacturing as a Service’. The manufacturing setup can become flexible and mobile due to the 5G ubiquity. AI-based solutions are enabling the manufacturing units to be predictive and profitable. Built on the speed and scalability of 5G technology, the industrial IoT (IIoT) is delivering breakthrough performances in the manufacturing sector. 5G is a catalyst for the digital revolution. It is generating multiple growth avenues across diverse business sectors.
Author bio:
Suresh Patel has worked as a Sales Engineer and held other management roles at Mermar Electronics. He brings 25 years of experience in printed-circuit-board sales and technical client service and managing business.