Diving into the forefront of industrial innovation, I’m thrilled to sit down with Vladislav Zaimov, a seasoned telecommunications specialist renowned for his deep expertise in enterprise telecommunications and risk management of vulnerable networks. With a career dedicated to advancing connectivity solutions, Vladislav offers unparalleled insights into the transformative power of private 5G networks in industrial settings. Today, we’ll explore how these cutting-edge networks are revolutionizing manufacturing, from enhancing operational efficiency to enabling futuristic technologies like digital twins. We’ll delve into specific deployments across major U.S. facilities, uncovering the challenges they’ve overcome and the unique benefits they’ve gained through private 5G.
Can you walk us through a recent project involving a private 5G network deployment at Hitachi Rail’s new plant in Hagerstown, Maryland?
Certainly, Diane. The project at Hitachi Rail’s Hagerstown facility is a fantastic example of how private 5G can serve as the backbone of modern manufacturing. This 307,000 square foot factory, which opened in September 2025, relies on a 5G network to streamline operations and support the production of up to 20 rail cars per month. The network acts as a digital foundation, enabling real-time data exchange across the plant. It’s been instrumental in integrating advanced tools like predictive maintenance, automated quality inspections, and digital twins, which are virtual replicas of physical assets. These technologies help anticipate equipment issues before they occur and ensure precision in production processes, significantly boosting efficiency.
How does the private 5G network specifically contribute to achieving such a high production rate at the Hitachi Rail plant?
The key lies in the network’s ability to provide ultra-reliable, low-latency communication. At Hitachi Rail, this means every connected device—whether it’s machinery or inspection tools—can communicate instantly and seamlessly. This minimizes downtime during production cycles and ensures that workflows are synchronized. For instance, data from sensors on assembly lines can be analyzed in real time to adjust processes on the fly, keeping the production of those 20 rail cars per month on track without bottlenecks. It’s about creating a truly connected ecosystem where every element of the factory operates in harmony.
Why do you think large factories in the U.S. have become a focal point for private 5G network deployments?
Large factories are ideal candidates for private 5G because of their scale and complexity. These facilities often span massive areas and involve hundreds, if not thousands, of connected devices and systems. Traditional Wi-Fi networks struggle to provide consistent coverage and reliability under such demanding conditions. Private 5G, on the other hand, offers dedicated bandwidth, enhanced security, and the ability to handle high device density. In the U.S., where manufacturing is a cornerstone of the economy, adopting this technology helps companies stay competitive by maximizing uptime and integrating automation. It’s a strategic move to future-proof operations in an increasingly digital industrial landscape.
Speaking of other U.S. facilities, can you share some details about the private 5G network at LG Electronics’ home appliance factory in Tennessee?
Absolutely. The LG Electronics plant in Clarksville, Tennessee, is another standout deployment. This facility faced significant challenges with their Wi-Fi system, particularly when it came to supporting automated guided vehicles (AGVs) and autonomous mobile robots (AMRs)—about 200 of them in total. Wi-Fi reliability issues led to communication lags, which disrupted workflows. By implementing a private 5G network with around 50 CBRS small cells, we’ve provided a robust solution that ensures seamless connectivity. This has dramatically improved the performance of AGVs and AMRs, allowing them to navigate and operate without interruptions, ultimately enhancing productivity across the factory floor.
Across various major U.S. manufacturers like Ford and Tesla, what’s a unique aspect of one of these private 5G deployments that stands out to you?
I’d highlight Ford’s Rouge Electric Vehicle Center in Michigan as particularly noteworthy. What’s unique there is how the private 5G network integrates with their electric vehicle production line to support real-time data analytics. This setup allows Ford to monitor every stage of assembly with incredible precision, from component tracking to quality control. The network’s low latency ensures that any anomalies are detected and addressed instantly, which is critical for maintaining the high standards required in EV manufacturing. It’s a perfect example of how 5G can tailor solutions to very specific industrial needs, creating a smarter, more responsive production environment.
How does your own 5G Smart Factory in Lewisville, Texas, leverage private 5G to push the boundaries of manufacturing technology?
Our 5G Smart Factory in Lewisville is essentially a living lab for innovation. We use private 5G to test and refine cutting-edge manufacturing processes in a real-world environment. The network supports a range of applications, from IoT-enabled equipment to advanced automation systems. It allows us to simulate and optimize factory scenarios, like integrating new robotics or streamlining supply chain logistics, before rolling them out to clients. The high-speed, secure connectivity of 5G lets us experiment with technologies like augmented reality for worker training and real-time monitoring for operational efficiency. It’s a sandbox for proving what’s possible with this technology in industrial settings.
Looking ahead, what is your forecast for the future of private 5G networks in industrial applications?
I’m incredibly optimistic about the trajectory of private 5G in industrial environments. Over the next few years, I expect adoption to accelerate as more companies recognize the competitive edge it provides. We’ll likely see even deeper integration with emerging technologies like artificial intelligence and machine learning, enabling predictive analytics on a scale we haven’t seen before. Additionally, as costs for deployment come down and spectrum availability improves, smaller manufacturers might start jumping on board. The focus will shift toward creating fully autonomous factories where every process is interconnected and self-optimizing. Private 5G will be the linchpin of this industrial revolution, transforming how we think about production and efficiency.
