Hitachi’s Private 5G Powers Digital Manufacturing in Maryland

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Hitachi has taken a major step forward in digital manufacturing at its new rail factory in Hagerstown, Maryland, by deploying a dedicated private 5G network. Developed in partnership with GlobalLogic and Ericsson, the network provides the foundation for a new level of automation, worker safety and real-time data intelligence.

The 307,000 square foot facility is designed as a digital-first production site capable of manufacturing up to 20 railcars per month. With rising demand for modern rail systems across North America, Hitachi is positioning this site as a model for advanced industrial operations.

Private 5G is central to this ambition. The reliable, high-bandwidth and ultra-low latency connectivity is already enabling applications that would be difficult to achieve securely and consistently on Wi-Fi or public networks. Real-time communication between machines, tools, sensors and digital systems means processes can be automated, monitored and optimised with precision. Predictive maintenance, intelligent transport of materials within the factory and advanced quality assurance are all enhanced through seamless connectivity.

One early innovation at the Hagerstown plant involves automated inspections using Spot, the robotic dog from Boston Dynamics. Working alongside Hitachi, Ericsson and Slalom, the robot performs high-resolution visual checks on railcar components. Images and sensor data are sent securely over the private 5G network to an AI-powered vision system that identifies defects and alignment issues. This approach improves inspection accuracy, reduces manual workload and increases worker safety by removing the need for teams to access challenging environments during checks. The data gathered throughout production also supports faster issue resolution when trains are in service.

Beyond robotics, the site uses digital twins to simulate and refine manufacturing processes before production, helping reduce errors and shorten delivery timelines. Edge computing integrated with the private network supports real-time analytics and decision-making on the factory floor, while the connectivity enables safer human-machine collaboration and intelligent automation systems.

The Hagerstown deployment highlights how private 5G is becoming a key building block for modern industrial environments. It shows how dedicated wireless networks can improve safety, increase productivity, and support the shift towards flexible, software-defined manufacturing. It also reflects the growing importance of ecosystem collaboration. Hitachi, Ericsson, GlobalLogic and Slalom have worked together across multiple sites and labs to design, test and scale industrial 5G and AI applications. This shared innovation model will likely be essential for accelerating Industry 4.0 adoption more widely.

As factories evolve, data and connectivity will play an increasingly strategic role in decision-making, performance optimisation and workforce enablement. Hitachi’s Maryland facility demonstrates how private 5G can serve as the digital backbone of next-generation manufacturing and points to a future where rail production, and heavy industry more broadly, are driven by automation, autonomy and intelligent digital systems.

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