As the artificial intelligence (AI) revolution continues to gain momentum, a growing number of industries are eager to harness the latest AI technologies to boost efficiency and improve business outcomes. This is especially important in manufacturing, where data analytics and intelligent automation technologies are essential to fully realize Industry 4.0 and 5.0 today, as well as next-generation Industry 6.0 in the future.

However, an enterprise’s ability to effectively utilize advanced AI applications depends on the speed, quality and reliability of network connectivity. For manufacturers, this connectivity is often wireless by necessity to cover the entire production facility, reach every corner of the warehouse, and extend out across the fabrication yard. Wireless technologies also offer the flexibility to quickly reconfigure layouts, enabling manufacturing operations to adapt to changing needs.

While Wi-Fi networks have historically met the basic wireless connectivity needs of some manufacturing operations, they increasingly fall short in more complex, high-demand industrial environments. Consequently, private wireless networks based on LTE and 5G technology are becoming integral to manufacturing process modernization.

In fact, the private network market is now forecasted to reach $7 billion by 2029, driven in large part by manufacturing and trends toward digital transformation and AI adoption. Yet, we’ve seen grand claims about private 5G that have not materialized. So, why now? And how will this communications evolution empower smart manufacturers to improve efficiency and profitability?

Manufacturing efficiency

As factories become more complex — integrating advancements like internet of things (IoT) sensors, autonomous production lines, and AI-driven analytics — legacy Wi-Fi networks are struggling to keep up. Modern manufacturing environments require fast, reliable and secure network connectivity that supports mission-critical applications and a broad range of connected machines and sensors, enabling them to collect and process increasing amounts of information reliably and securely.

This transformation has paved the way for private wireless networks composed of dedicated LTE or 5G wireless infrastructure, which are operated by enterprises themselves. In manufacturing environments, private wireless networks typically operate over licensed or shared spectrum, such as Citizens Broadband Radio Service (CBRS) in the U.S., and provide mobile connectivity for a defined group of users and devices.

With promises of improved wireless coverage, lower latency, enhanced security and greater reliability, these networks support the deployment of connected machinery and advanced applications that drive efficiency and foster innovation in manufacturing operations. For example, leading equipment manufacturer John Deere recently deployed private 5G in its Waterloo, Iowa, plant to boost network capacity with a smaller footprint and improved reliability compared to Wi-Fi.

Connectivity and control

Manufacturing environments can pose distinct wireless connectivity challenges stemming from vast indoor and outdoor footprints, dense machinery configurations and complex layouts. Conventional Wi-Fi networks struggle to deliver reliable coverage in these settings, hindered by regulatory power limitations, signal interference between access points, and ever-changing RF conditions caused by moving equipment and materials. Private wireless networks address these challenges by using dedicated spectrum and custom antenna configurations engineered for comprehensive facility coverage.

Unlike public networks operated by mobile network operators, private wireless solutions provide manufacturers full control of their connectivity infrastructure. This allows for precise optimization of coverage, performance and security. With a dedicated system on premise, enterprise network administrators can efficiently manage connected devices, data flow and network traffic, all while reducing exposure to external cyber threats, safeguarding sensitive data and proprietary processes.

Driven by innovation

With a foundational connectivity layer in place to connect machinery and sensors to collect data, manufacturers can leverage private wireless networks to support a wide range of value-added services and applications, enhancing productivity and improving their business processes. The ability to employ AI processing at the edge of the network enables quick decision-making and local processing, as well as intelligent use cases such as biometric applications, mobile sensors for data extraction, predictive maintenance and generative AI inferencing.

Seamless wireless connectivity equips manufacturing environments to be powered by functions like automation, robotics, intelligent AI, real-time analytics and radio frequency identification (RFID) inventory tracking. As a result, private networks can drive a wide range of innovative enhancements, including:

• AI-driven analytics: Ultra-low latency ensures that AI applications react quickly and precisely.
• Asset tracking: Seamless connectivity for RFID readers, real-time location system (RTLS) scanners and IoT-connected sensors, improving inventory accuracy and traceability.
• Predictive maintenance: Facilitating real-time collection and analysis of machine data to help avert unexpected and costly equipment failure.
• Industrial automation: Consistent connectivity facilitates real-time communication between machines and sensors in automated production lines or automated guided vehicles (AGVs).
• Digital twins: Using real-world data from sensors and connected devices to create real-time virtual simulations that help optimize manufacturing processes.
• Physical security: Connected closed-circuit cameras that use facial recognition.
• Employee safety: Monitoring areas with IoT-connected devices to identify chemical spills and alert personnel, reducing accidents and liability costs.

Partner for success

Yet, despite all the clear benefits of private networks, some research suggests that market adoption still may not reach its full potential due to the complexity of network deployment and integration. Although enterprises may realize they need private wireless connectivity to leverage new, innovative approaches and advanced AI applications, they are unlikely to have the necessary skills and resources in-house.

To address their networking needs while still focusing on their primary business goals, manufacturers often opt to partner with managed service providers (MSPs) or system integrators with proven expertise in private wireless network deployment. Moreover, many MSPs bring deep knowledge of network architecture, regulatory requirements and industry-specific needs to deliver network solutions that are tailored to manufacturing environments, operational scales and budget constraints. By relying on network experts, manufacturing enterprises can both reduce risk and direct their resources toward their primary business priorities.

Empowering tomorrow’s industry

The manufacturing environment is dynamic by nature. Smart manufacturing demands high-performance, reliable and secure networks that allow companies to connect, analyze and act on data in real time. As manufacturers strive to more fully embrace the AI revolution, private wireless networks will be a critical component to enable true digital transformation of manufacturing environments. By providing robust, secure and scalable connectivity, private wireless enables a new class of intelligent applications that boost productivity, enhance safety and drive innovation, paving the way for a seamless evolution beyond Industry 4.0.

Ryan Pettijohn leads 1Finity‘s private wireless practice, driving offer development and collaborating with clients and partners to deliver high-value wireless solutions for enterprises and service providers. Prior to joining 1Finity, Ryan held solution development, business analytics and network engineering roles at Fibertower, Genuity and GTE. Ryan holds a BSEE degree from Purdue University, and an MBA from the University of Dallas.