Vertical: Manufacturing
Application: Digital twins, Predictive maintenance, Automated quality inspections, IoT-driven material transport
Ecosystem: Ericsson, Globallogic
Private Network: 5G
Hitachi Rail has deployed a private 5G network at its manufacturing facility in Hagerstown, Maryland, creating what the company calls a blueprint for future rail production worldwide. The 307,000 square-foot factory operates on dedicated 5G infrastructure designed by GlobalLogic and powered by Ericsson technology.
The deployment represents Hitachi’s “One Hitachi” approach, leveraging synergies across the conglomerate’s technology divisions. GlobalLogic, acquired in 2021, served as system integrator, while Ericsson provided core infrastructure. This collaboration demonstrates how companies can combine internal expertise with external partnerships for digital transformation.
The private 5G network enables advanced manufacturing applications. Physical AI, enabled by real-time data capture and analysis, allows intelligent systems—such as inspection robots or robot dogs—to detect defects and support on-site additive manufacturing for spares and tooling. This extends beyond automation to sophisticated quality control operating autonomously throughout production.
Digital twins receive enhancement through high-bandwidth, low-latency characteristics. Digital twins, powered by high-bandwidth, low-latency connectivity, enable engineers to simulate and optimize railcars before production, reducing errors and accelerating time to market. Virtual modeling allows engineers to test designs digitally before physical production.
Predictive maintenance processes real-time data streams throughout the facility. Predictive maintenance, driven by secure, real-time data over private wireless, helps anticipate failures, reduce downtime, and optimize equipment performance. This shifts from reactive maintenance to data-driven intervention strategies.
Material handling has been revolutionized through IoT-enabled transportation. IoT-driven material transport, enabled by seamless connectivity, allows automated vehicles and devices to move materials safely and efficiently across the factory floor. This optimizes material flow and reduces human error.
The Hagerstown facility produces up to 20 railcars monthly and serves North American markets. The facility’s capabilities position it to meet growing demand for rail transportation while demonstrating Industry 4.0 applications in heavy manufacturing.
Joe Pozza, President of North America at Hitachi Rail, stated: “Our new digital factory in Hagerstown is more than just a train manufacturing site – it is a blueprint for the future of rail production worldwide, harnessing the latest AI, robotics, and digital systems to deliver high-quality, smart, and reliable manufacturing.”
Alan Minney, Senior Director of Global Strategic Partnerships for Enterprise at Ericsson, emphasized: “To make Industry 4.0 real, manufacturers need secure, high-performance connectivity that is flexible and scalable. This project in Hagerstown shows how private 5G can power everything from predictive maintenance to collaborative robotics, while reducing energy usage and downtime.”
Sameer Tikoo, General Vice President of GlobalLogic’s Communications & Network Provider Business Unit, explained: “Private 5G networks are unlocking new opportunities for industries, from advanced automation to energy optimization. It’s more than faster connectivity—it’s about establishing the resilient digital backbone that modern industrial operations need to compete, grow, and achieve sustainability goals.”
