Five ways 5G unlocks IoT in Industry 4.0 – and three places to do it

Advances in automation have impacted every sector, but probably none more so than manufacturing. Traditional assembly lines are being replaced by intelligent factories where machines not only perform assembly, but also help optimize resources and reduce costs. This technological revolution, known as Industry 4.0, is becoming a reality, thanks in no small part to the Industrial Internet of Things (IIoT) and the availability of private 5G networks.

By 2029, the Industry 4.0 market is expected to be worth $377.3 billion. Machines, robots, sensors, people and drones all require seamless connectivity in IIoT. Previous generations of wireless networks could not support these enormous communications needs. That is why 5G is crucial for Industry 4.0. 5G not only improves connectivity, it also offers several benefits that fuel this Industry 4.0 revolution. These include:

1 | Higher data rates and higher bandwidth

5G offers data transfer speeds of up to 20 Gbps, more than twenty times faster than 4G. This enables the rapid transfer of large amounts of data from devices, machines and sensors in industrial environments.

2 | Extremely low latency

With a latency of just 1 millisecond, 5G enables IIoT technologies to communicate at unprecedented speed. Imagine the benefits of monitoring production lines, machines and equipment in real time.

3 | Improved reliability and availability

Connectivity disruptions are an accepted part of previous generations of wireless networks. However, 5G supports consistent connectivity even in remote industrial environments.

4 | Enhanced edge computing capabilities

5G can be combined with edge computing to facilitate data processing and analysis at or near the source, supporting real-time decision making for IIoT systems.

5 | Massive device connectivity

The latest generation of wireless technology can simultaneously support up to a million connected IoT devices, sensors and robots, which is critical given the technical complexity of Industry 4.0.

The combined benefits enabled by these technological features pave the way for a variety of new Industry 4.0 use cases. This includes:

1 | Smart warehouses

Thanks to the high bandwidth offered by 5G, warehouses can support large, distributed networks with numerous connected devices and sensors for improved inventory management and process optimization. Additionally, 5G’s ultra-low latency ensures inventory tracking, machine control, robot operation, and other data-intensive tasks have real-time processing and communications capabilities. This improves productivity, reduces labor costs and ensures more reliable warehouse communications.

2 | Predictive maintenance

Another benefit of 5G is the ability to predict equipment failures and proactively address issues before they impact business operations. Predictive maintenance prevents downtime and extends the lifespan of machines. Additionally, manufacturers can make fine-tuned adjustments by continuously monitoring machine status to maintain production standards.

3 | Flexible production

5G provides more flexibility in the production process. Robots and drones are not limited by connectivity issues, making material handling and logistics more flexible. As the technology matures, it will provide a vital link between factories and the market, allowing manufacturers to respond efficiently to changing demands or external logistics challenges.

The ability to collect, analyze and update data in real time is crucial for Industry 4.0. Armed with this intelligence, manufacturers can make real-time adjustments to address quality issues, inefficiencies and safety concerns, speed up production processes and reduce costs.

Testing with digital twins

5G is crucial for realizing the potential of Industry 4.0. However, these capabilities need to be tested to ensure they work as expected and this requires integrating digital twins. These virtual models of physical systems use data from sensors and other sources to create an emulation that tests how the system will behave under different conditions. This allows manufacturers to evaluate 5G infrastructure, explore use cases and determine the best way to integrate the network.

For example, engineers can use the simulation to evaluate the optimal configuration of machines, sensors and robots, identify potential bottlenecks that could occur during periods of high production, and implement a plan to avoid that scenario. Digital twins and 5G are already fueling Industry 4.0 innovations, and this will only increase as adoption increases.

With 5G, smart factories will become a reality, enabling a range of innovative manufacturing concepts that will improve productivity and efficiency. Advances in augmented reality will open up new possibilities for remotely accessing and troubleshooting manufacturing equipment, with real-time overlays to guide the complex process. Expect to see these and many more use cases as the Industrial Revolution accelerates, with 5G capabilities holding the key to unlocking Industry 4.0.