Unlocking the potential of 5G for industrial automation
- By Aurélien Le Sant
- 18 Sep 2025
- 3 min read
The global adoption of 5G mobile network technology is expanding at an unprecedented rate, with forecasts suggesting that 5G-enabled networks will generate $13.2 trillion in opportunities worldwide by 2035, according to the World Economic Forum.
In industrial automation markets, 5G represents not only a technical evolution but also an opportunity to reshape processes for improved scalability, reliability, and sustainability.
Industries are already exploring how this technology can support cutting-edge applications such as augmented reality (AR), artificial intelligence (AI), and autonomous systems.
Figure 1 shows that the manufacturing sector is expected to be the largest beneficiary, specifically being able to leverage 5G to enhance operational efficiency, increase production flexibility, and enable data-driven decision-making.
5G technology introduces three primary communication capabilities tailored to industrial environments:
1. Enhanced mobile broadband (eMBB)
2. Ultra-reliable low-latency communication (URLLC)
3. Massive machine-type communication (mMTC)
These three capabilities address many needs of industrial automation environments, without needing to implement multiple wireless technologies, as seen in Figure 2. Other key benefits 5G can bring to industries includes enabling seamless data exchange, supporting large-scale sensor connectivity, and providing real-time control for mission-critical processes. With these features, 5G allows industries to scale operations, track assets with precision, and support autonomous machinery with high-speed data processing.
In addition, 5G networks can function on public or private infrastructure. Private 5G networks provide localized solutions, enabling manufacturers to configure secure and reliable systems that prioritize their unique requirements.
Figure 2: Industrial applications addressed by the different 5G communication capabilities
The value of 5G becomes most evident when applied to real-world industrial challenges. We explored several use cases, with three standing out for their potential impact on industrial operations.
Flexible manufacturing lines
Modern manufacturing facilities require agility to scale production in response to demand. Traditional wired setups often make reconfiguration time-consuming and costly. By integrating 5G, manufacturers can enable wireless connections between controllers, devices, and execution systems, ensuring faster adaptation of production layouts. With 5G’s low latency and reliable communication, manufacturing lines can be adjusted efficiently, enhancing productivity while reducing downtime.
Machine vision for maintenance
Embedding high-resolution cameras within machinery enables manufacturers to capture live video streams for diagnostics and failure analysis. With 5G’s bandwidth capabilities, these video streams are transmitted rapidly to analysis servers, reducing troubleshooting time and minimizing disruptions. AI-powered diagnostic tools leverage this data to automate issue detection, ensuring continuous operations. This application showcases how 5G elevates preventive maintenance efforts through enhanced visibility and automated insights.
Remote assistance using AR/VR
For industries operating in remote or complex environments, providing real-time guidance to on-site workers can be a challenge. With 5G-enabled augmented and virtual reality smart glasses, employees receive live support from experts located offsite. The technology’s high bandwidth and low latency ensure seamless communication, enabling maintenance tasks to be performed efficiently and safely.
We have implemented private 5G installations to explore the value it can bring to flexible manufacturing environments. In our Shanghai smart factory, we integrated 5G core solutions on-premises, enhancing operational control and enabling more adaptable production lines. By leveraging 5G, the factory increased the production lines’ load rate to 80% while reducing required space by 50%.
Our Shanghai smart factory experiments also demonstrated the importance of tailoring deployment strategies to local regulations and spectrum licensing requirements. By collaborating with 5G operators and integrators, we gained invaluable insights into region-specific approaches and technologies that drive success in unique environments.
An additional notable application of 5G we explored involves hoisting systems. Traditional wired solutions for crane communication are often prone to cable breakage, leading to safety concerns and increased maintenance costs. By replacing these fragile connections with a 5G-enabled communication systems, cranes can be operated remotely with high reliability and low latency.
In our R&D lab, testing revealed that 5G provided a twofold improvement in roundtrip response time compared to combined Wi-Fi and proprietary wireless solutions. Additionally, the 5G setup reduced the carbon footprint for a site operating more than ten cranes, from 50 kg of CO₂ per crane to just 33 kg.
For businesses assessing private 5G networks, key questions include timing, ROI potential, and whether existing wireless technologies may be sufficient. Deployment complexities and skill gaps within IT and operational teams are also considered risks linked to implementing this new technology.
Initial costs for 5G hardware and software can exceed those of alternative technologies like Wi-Fi 5. However, our analysis shows that as the number of connected devices increases, 5G becomes cost-competitive, offering added functionalities such as remote control capabilities and reduced maintenance efforts.
Addressing these challenges requires a three-step approach:
· First, set up strategic partnering – collaborating with experienced consultants and system integrators can simplify the assessment and deployment process. These experts can help identify barriers, evaluate ROI, navigate the complex regulatory environment and mitigate risks.
· Pre-testing is key to validating the solution – conducting integration tests with 5G-enabled devices ensures compatibility and performance before deployment. This includes evaluating whether applications require native 5G connectivity or gateways.
· Optimization is ongoing – industrial sites must continually monitor and refine 5G networks to align with evolving technologies and operational demands. For instance, leveraging URLLC capabilities as they mature can further enhance determinism and reliability.
First, set up strategic partnering:
Collaborating with experienced consultants and system integrators can simplify the assessment and deployment process. These experts can help identify barriers, evaluate ROI, navigate the complex regulatory environment and mitigate risks.
Pre-testing is key to validating the solution:
Conducting integration tests with 5G-enabled devices ensures compatibility and performance before deployment. This includes evaluating whether applications require native 5G connectivity or gateways.
Optimization is ongoing:
Industrial sites must continually monitor and refine 5G networks to align with evolving technologies and operational demands. For instance, leveraging URLLC capabilities as they mature can further enhance determinism and reliability.
By 2030, 5G is expected to become the standard wireless connectivity solution in industrial environments. As industrial 5G continues to evolve, new standards like Reduced Capacity (RedCap) and features such as advanced geolocation services are expected to expand its applicability across various use cases.
Innovations such as beamforming technologies are poised to reduce electromagnetic pollution and improve energy efficiency, supporting sustainability goals. Additionally, combining 5G with complementary technologies like AI, edge computing, time sensitive networking (TSN) and robotics will open doors to unprecedented automation opportunities.
For businesses committed to operational excellence, investing in 5G represents a forward-looking decision to build capabilities that meet current and future challenges.
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