Connectivity on the factory floor is more important than ever to transmit the large amounts of data that will make Industry 4.0 a reality for all. The transition from wired connections to wireless is underway, allowing factories to make leaps in mobility and scalability.
While Wi-Fi has been a standard method of connecting devices and enterprise applications, it was not built for the demands of industrial automation and has its shortcomings. Wi-Fi can also potentially leave networks vulnerable to cybersecurity attacks, in part because it often relies on less robust authentication protocols.
Another solution is available: 5G.
The fifth generation of wireless communication, 5G sends data across dedicated ranges of the radio frequency spectrum offering ultra-fast speeds and ultra-low latency in some configurations. Security and network integrity are key strengths, as MxD has demonstrated.
It can be the right solution for many applications, allowing for massive connectivity, greater reliability and security, and network slicing.
As manufacturers consider the transition from wired connections or Wi-Fi to 5G, a key question is whether they can undertake the upgrade themselves, or if they need outside help.
The setup, configuration, optimization, access control, and maintenance of a private network require skills and capacity.
Here’s a checklist of questions manufacturers should task and conditions to evaluate as they make that decision:
Step 1: Evaluating Internal Technical Expertise
Manufacturers must assess the capabilities of their existing information technology (IT) and operational technology (OT) teams. Are there in-house engineers or network specialists who understand cellular technologies? A capacity check is needed: Can current staff manage deployment, maintenance, and troubleshooting of a 5G network?
Step 2: Assessing Infrastructure Readiness
A site survey will determine if the physical structures of a factory, such as walls, metal equipment and layout, are favorable for 5G propagation. Companies must also determine if they have the backbone in fiber and power supply to support 5G radios and other equipment needs.
Within the factory setting, device compatibility must also be assessed: Are existing internet of things (IoT) sensors, robots, and machines 5G-ready or upgradeable?
Step 3: Determining Spectrum Access
When building a private network, a key decision is what spectrum band to use. Manufacturers need access to regulated spectrum with enough bandwidth to provide the capacity they need. The spectrum has several segments. Do you know which portion of the spectrum best fits your needs?
Low: The Sub-gigahertz (GHz) frequency bands support wide area coverage as the attenuation is lower and radio waves penetrate different materials. The spectrum is scarcest at these low frequencies.
Mid: This is Sub-6 GHz frequency range but larger than 1 GHz and offers expanded device capacity and reasonable bandwidth for narrowband and broadband services.
High: Millimeter-wave, especially 26 GHz, 28 GHz, and 40 GHz, is able to support advanced broadband services for high-resolution video streaming and virtual reality (VR) and augmented reality (AR). This range offers the fastest speeds across short distances, making it ideal for high-traffic data, at the cost of reduced coverage. Millimeter wave spectrum has a smaller radio footprint due to the radio frequency propagation characteristics and relies on beamforming, which directs wireless signals toward a specific receiver or target instead of broadcasting them in all directions.
To choose the right spectrum band, firms must analyze their network’s coverage area, capacity demands, and latency requirements to identify the appropriate spectrum band. MxD has compiled information on the characteristics of each spectrum band.
Other factors that affect spectrum selection include:
- Reliability and performance: Licensed or shared spectrum obtained in coordination with a Spectrum Access System (SAS), which is a service that manages and authorizes access to the Citizens Broadband Radio Service pectrum band, offers greater predictability and protection against interference, and is suitable for mission-critical applications.
- Cost: Unlicensed spectrum generally involves lower upfront costs but may come with performance trade-offs due to potential interference.
- Complexity: Licensed spectrum often entails a more complex licensing process compared withshared or unlicensed spectrum.
Step 4: Confirming Security and Compliance Capability
5G networks provide advances in security that come with private cellular systems. A private network requires specifically designated SIM cards to grant devices access to that network, creating an additional physical layer of security. Furthermore, the deployment of a private 5G network allows all connectivity infrastructure to remain on premises.
Security is more important than ever in Industry 4.0. Is your team skilled in cybersecurity? Can your internal team manage the new security perimeter, SIM authentication, and potential new attack surfaces that come with 5G?
Manufacturers may also need external help with ensuring compliance with industry standards like those from NIST and ISO.
Step 5: Evaluating Business and Operational Costs and Benefits
Can your internal staff model the return on investment of switching to 5G versus other solutions? Evaluating the benefits and costs of implementing 5G in a manufacturing environment requires a strategic, use-case-driven approach. Manufacturers should make their assessment based on specific operational goals like automation, real-time monitoring, or flexible production. MxD has gathered information on financial returns from a switch to 5G.
Real gains can be made in efficiency, speed, materials savings and maintenance, but they must be validated against use cases, such as automated guided vehicles, real-time analytics, and AR/VR tools that enable training and maintenance.
Step 6: Planning for Integration and Lifecycle Support
A change to 5G involves planning for a full lifecycle of technology, including design, deployment, testing, and updates. Is your team prepared to undertake all steps in the lifecycle?
Step 7: Planning for business continuity during changeover
Manufacturers must put business continuity on their checklist for potential digitalization partners as they consider a changeover to 5G. It’s a challenge, but businesses need to upgrade infrastructure in a way that does not affect their ability to produce. Are you prepared for this challenge?
Manufacturers should begin with a comprehensive risk assessment and phased implementation plan, and invest in staff training to ensure smooth adaptation and troubleshoot potential issues.
Finding Partners
If manufacturers have expertise gaps within their internal skill sets, they could look to outside partners to help execute the project.
Because private wireless networks are relatively new to manufacturing, firms might not have a team of cellular experts needed to plan, design, install, and operate the system.
Major cellular network equipment and software providers have the experience and resources to build, optimize, and maintain networks, and they provide the end-to-end solution with compatibility guarantees. This is a more traditional and safe route, but can be more costly.
Manufacturers that take that route should look for partners that can offer a managed service package, which would include network monitoring, security monitoring, patch and upgrades management, network optimization for new use cases, and break-fix repair, with a service level agreement that meets their expectations.
There are a number of private network providers in the United States that can offer private wireless as a service, delivering network design and installation, and then securely managing network operation to meet manufacturers’ performance requirements.
Familiarity with fundamentals such as spectrum, capabilities, and equipment is the crucial starting point ahead of a transition.
