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Ericsson USA 5G Smart Factory

Smart Manufacturing

 

At the Ericsson USA 5G smart factory, we manufacture the equipment that will power 5G networks across the U.S. The factory is a full scale operation realizing the potential of 5G with Industry 4.0 to enable intelligent automation and leverage real time data across operations.

Ericsson has been connecting the United States for nearly 120 years. As a trusted partner to major service providers and many regional carriers across the country, we have been strengthening our investments in the U.S. to be even closer to our customers. The 5G smart factory will help accelerate 5G deployment, which will give the U.S. a first-mover advantage, create new jobs, and usher in a new era of technological advancement.

Products built in the factory are Build America, Buy America (BABA) compliant.

USD 150 m
investment
> 500
new jobs created
300000
sq. ft.
1 st
Build America, Buy America (BABA) compliant 5G products

Building the future of 5G in the USA

Ericsson’s USA 5G Smart factory in Lewisville, Texas is at the forefront of building the next generation of 5G infrastructure. We are investing in the US to build resilient and secure supply chains, create US jobs, and ensure continued US 5G leadership. With network technology made in Texas, Ericsson is committed to driving innovation, economic growth, and technological excellence in the United States.

Ericsson USA 5G Smart Factory recognized as ‘Global Lighthouse’ by the World Economic Forum

Ericsson’s USA 5G Smart Factory in Lewisville, Texas, has been recognized by the World Economic Forum as a global front runner in the Fourth Industrial Revolution (4IR). The Forum has awarded the site with its prestigious “*Global Lighthouse” designation in recognition of Ericsson’s deployment of next-generation technology at the site and its subsequent impact.

Learn More

The 5G smart factory produces 5G and Advanced Antenna System radios to boost network capacity. The state-of-the-art factory is equipped with fast and secure cellular connectivity.  It is a highly automated 5G smart factory and sets a precedent for how smart manufacturing can optimize processes for efficiency and increase production through automation.

The 5G smart factory is an example of Ericsson’s investment in the U.S. It enhances our secure supply chain, assembling Ericsson's 5G equipment close to our U.S. customers.

Use cases

Use cases are a way of sharing how we are solving real problems with technology. The Ericsson USA 5G Smart Factory use cases cover a wide range of application areas that can solve business challenges for a variety of contexts. Some of the factory’s key use cases are highlighted below.

Explore how CBRS-based smart wireless connectivity is empowering Industry 4.0 Ericsson

Energy monitoring and management

Energy monitoring and management


Factories are held responsible for a significant amount of energy usage. Lack of visibility into energy consumption at the device-level prevents factory management from incorporating optimization strategies. This 4G connected energy monitoring and management solution gathers data of all energy appliances in the factory for tracking. By doing that, it can show real-time energy consumption as well as turn particular appliances on/off based on preset rules. Factory energy consumption can be reduced by 5 percent.

Challenge
  • Buildings, including factories, use 40 percent of our energy and 70 percent of our electricity
  • Lack of visibility into energy consumption at the device-level prevents optimization strategies
Solution
  • Enables monitoring of all energy appliances and ability to turn them on/off based on rules
  • Gathers data out of the building management systems (BMS) for tracking in the data lake and shows real-time energy consumption on big screen
Estimated impact
  • Cost: 5 percent reduction in energy bill from better monitoring and control of energy consumption
  • Visibility: Better visibility into actual power consumption leads to increased ability to negotiate power consumption unit price from energy providers
Potential applications
  • Manufacturing
  • Agriculture
  • Retail & smart buildings
 

Augmented reality for remote support

Augmented reality for remote support


Maintenance in factories is difficult due to a lack of on-site expertise. Having maintenance labor maintained at each site, and flying the vendor out for repairs is expensive.

The cost is high for maintenance labor maintained at each site, and flying the vendor out for repairs is also costly 5G powered Augmented reality (AR) will provide factory teams with virtual guidance from experts to troubleshoot and repair equipment. The system with a headset can share audio, video, and annotations in real time for quicker and more precise support wherever the service people are around the world. The augmented reality support will decrease labor, travel, and vendor costs as well as increasing equipment uptime.

Challenge
  • With nearly 27 percent of US manufacturing workers set to retire over the next ten years, it will be increasingly difficult to complete certain repairs due to lack of on-site expertise and specialized knowledge
  • The cost is high for maintenance labor maintained at each site. Flying the vendor out for repairs is also costly.
Solution
  • Augmented reality headsets used by maintenance teams to troubleshoot and repair equipment by:
    • Connecting to central or vendor support teams
    • Getting step-by-step, system generated and knowledge-base powered guidance in real time
Estimated impact
  • Labor: 10 percent decrease in plant maintenance labor
  • Downtime: 5 percent decrease in equipment downtime because of more efficient troubleshooting
  • Cost: 20-25 percent reduction in vendor service cost
  • Travel cost: 40-50 percent reduction in travel cost
Potential applications
  • Manufacturing
  • Energy & Utilities
  • Healthcare
 

Digital adherence for safety and quality

Digital adherence for safety and quality


Helmets, electrostatic discharge jackets, eye protection, and shoe coverings—safety and security for both employees and visitors in facilities like factories are of the utmost importance. However, it is both time-consuming and cumbersome to manually check everyones adherence to safety and quality rules. The video analytics platform uses a camera to detect attire and objects and notifies whether safety attire is used or not. The right equipment could improve compliance and reduce incidents in the facility by 10 percent.

Challenge
  • As manufacturing becomes increasingly connected, enterprises need to find more modern ways to ensure safety and security for both employees and visitors
  • Manually checking that employees and visitors are adhering to safety and quality rules by, for example, wearing safety jackets and shoe covers is cumbersome
Solution
  • Video analytics platform with attire detection that notifies with a “yes” or “no” whether visitors and employees are wearing safety jackets, shoe covers, hearing and eye protection
  • The platform can detect people, objects and events
Estimated impact
  • Compliance: 10 percent improvement in compliance and reduced incidents
Potential applications
  • Manufacturing
  • Energy & Utilities
  • Healthcare
 

End-to-end digital thread for radio production

End-to-end digital thread for radio production


Machine downtime causes a significant cost for manufacturers. Lack of component history makes troubleshooting the root of the failure difficult, costly, and time-consuming. The end-to-end digital thread solution gathers and logs a complete history of each radio’s components, supplier info, test results, and tracking from previous troubleshooting. The single source of truth enables a rapid root-cause analysis which reduced repair costs by approximately 20 percent.

Challenge
  • Unplanned downtime costs USD 50 billion per year for manufactures globally
  • Lack of component history makes it difficult to identify root cause of failures leading to: machine downtime, more rework and higher repair costs, and recurring failures
Solution
  • A complete history of each radio’s components and production including: supplier info, test results, troubleshooting and who it’s performed by
  • Single source of truth (in the data lake) for the radio’s history enabling rapid root-cause analysis
Estimated impact
  • Cost: 15-20 percent reduction in repair costs from less machine downtime, rework and fewer recurring failures
Potential applications
  • Manufacturing
  • Healthcare
 

Machine learning based visual inspection

Machine learning based visual inspection


Visual inspections are often time-consuming and come with a high risk for error. Illumination conditions and background clutter impacts the ability of traditional machine vision inspections. By using a high-resolution camera and machine learning algorithms for visual inspections, the accuracy of the inspection is increased and inspection time is reduced.

Challenge
  • Visual inspections are time-consuming, and errors typically range from 20-30 percent
  • Traditional machine vision struggles to handle, for instance, illumination conditions and background clutter
  • High false positives and missing errors result in machine downtime and rework
Solution
  • Using a combination of high-resolution camera and machine learning algorithms, we improve the accuracy of the board inspection in the production area
Estimated impact
  • Labor: 5 percent decrease in inspection time
  • Throughput: 5 percent increase in throughput based on reduced false positive failures
Potential applications
  • Manufacturing
  • Energy & Utilities
 

Automated unpacking process

Automated unpacking process


Manual labor is traditionally used for 50-80 percent of factory activities. The decanting process, gradually unpacking and placing material from one container to another, is a labor-intensive activity. Material is not always delivered in uniform orders which is time-consuming to structure and organize. The automated robot identifies and picks up material from unstructured bins. The material is then placed onto trays in a particular orientation and location so it can automatically be received by production lines. Automation of the decanting process leads to a 50 percent decrease in labor kitting time and increases production uptime.

Challenge
  • A large share of factory activities (around 72 percent) are based on manual labor, such as unpacking and carefully placing components onto trays so that they can be picked up by automated lines
  • Material coming from overseas is not always delivered in uniform order
Solution
  • Pick up materials from unstructured bins and place them onto trays in a particular orientation and location so they can automatically be received by production lines
Estimated impact
  • Labor: 50 percent decrease in warehouse operators doing kitting
  • Uptime: 5 percent increase from more efficient unpacking
Potential applications
  • Manufacturing
  • Agriculture
 

Our people

The 5G smart factory provides access to innovative technologies and careers of the future. Our digitally skilled workforce is part of a team shaping the next innovation platform. Join our team.

Can a factory be smart, sustainable and create jobs?

Listen to Mark Hahn, a Senior Solutions Architect at Ericsson, and his story on being part of the team that created the revolutionary 5G Smart Factory in Lewisville, Texas, USA.

Recognized as a “Global Lighthouse” by the World Economic Forum, the Ericsson 5G Smart Factory is highly automated and efficient, while also powered 100% by renewable electricity.

24 %
more energy-efficient than baseline
17 %
of power required is produced by onsite solar panels
40000
gallon tanks to collect and reuse rainwater
Up to 5 x
reduction in shipping distance

Ericsson has established a target to be carbon neutral for company operations by 2030. Our investments in innovative and sustainable technologies will enable the smart factory to operate with net-zero carbon emission from building energy consumption and occupant transportation. Learn more about our climate action goals. Upon certification, the smart factory will be the first Ericsson facility globally to achieve both LEED Gold and LEED Zero Carbon certifications.

Find out how Ericsson is realizing sustainable 5G-enabled smart manufacturing in the U.S.

https://www.usgbc.org/leed

News and media

Featured

Expansion of USA 5G Smart Factory

Ericsson announces the next chapter of 5G manufacturing in North America with an expansion of the USA 5G Smart Factory.

 

Can a factory be smart, sustainable and create jobs?

Listen to Mark Hahn, a Senior Solutions Architect at Ericsson, and his story on being part of the team that created the revolutionary 5G Smart Factory in Lewisville, Texas, USA.

Recognized as a “Global Lighthouse” by the World Economic Forum, the Ericsson 5G Smart Factory is highly automated and efficient, while also powered 100% by renewable electricity.

More in manufacturing

5G for manufacturing

In an era of intense volatility due to shorter business and product lifecycles, manufacturing companies around the globe are under extreme pressure. Margins are being squeezed more than ever as components increasingly become more varied and complex to produce, workforces are aging and becoming costlier to maintain.

Smart manufacturing

The manufacturing industry is entering Industry 4.0. In the quest for lean manufacturing and smart production, petabytes of data are being generated and streamed for analysis. This makes safe and sustainable management of data and devices a challenge.

Welcome to the smart factory

The fourth industrial revolution has arrived, and it will transform manufacturing as we know it.

Contact us

Ericsson USA 5G Smart factory

2601 S. Valley Parkway,
Lewisville, TX, 75067

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Get in touch!

Questions? If you’re interested in learning more about Ericsson’s 5G Factory, please send us a message below.