Hitachi Rail adopts Private 5G Network Next-Gen Manufacturing

Hitachi Rail adopts Private 5G Network Next-Gen Manufacturing

Hitachi Rail’s state-of-the-art factory in Hagerstown, Maryland, is more than a manufacturing plant. It’s the template for what smart, connected rail production will look like in the coming decade. Through a collaboration with GlobalLogic, a Hitachi Group company, and Ericsson, the site now boasts a private 5G network that acts as the digital backbone of its 307,000-square-foot facility.

Capable of producing up to 20 railcars a month, the Hagerstown factory integrates ultra-low latency and high-bandwidth 5G to enable automation, predictive analytics, and safer working environments. The network is designed not just for today’s production needs but as a scalable foundation for future digital-first innovations in manufacturing.

Joe Pozza, President of North America, Hitachi Rail, explained the vision: “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. Private 5G connectivity is a game-changer for advanced manufacturing environments. This secure, high-performance connectivity allows us to automate more processes, protect our workforce, and accelerate innovation.”

Industrial transformation through private 5G

Private 5G networks are increasingly viewed as the linchpin of Industry 4.0. Unlike public cellular or Wi-Fi, private 5G offers higher security, dedicated bandwidth, and near-instant data transfer. These attributes make it particularly valuable in complex, high-stakes manufacturing environments where downtime or errors can carry significant costs.

At Hagerstown, the technology enables several next-generation industrial capabilities:

• Physical AI: Intelligent inspection systems, including robot dogs and automated inspection units, can detect defects in real time and even support on-site 3D printing of spares and tooling.

• Digital twins: Engineers can create live, high-fidelity simulations of railcars before production, reducing errors and accelerating time-to-market.

• Predictive maintenance: Continuous data collection allows machinery to be serviced before breakdowns occur, cutting downtime and improving performance.

• Automated quality inspections: High-resolution image analysis improves accuracy, ensuring every component meets strict safety and quality standards.

• IoT-driven material transport: Automated vehicles move materials seamlessly across the plant floor, reducing manual handling and improving safety.

Alan Minney, Senior Director of Global Strategic Partnerships for Enterprise at Ericsson, noted: “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.”

Building the digital-first rail factory

The Hagerstown facility stands as a milestone in Hitachi Rail’s ambition to drive sustainable mobility through innovation. The project not only meets the rising demand for modern rail manufacturing in North America but also showcases how digital systems can be embedded from the ground up to enhance efficiency and worker safety.

GlobalLogic played a critical role in making this vision a reality. Leveraging more than a decade of partnership with Ericsson, the company delivered consulting, integration, deployment, and lifecycle management services for the private 5G system. Their expertise extended from semiconductor-level technologies to full-scale cloud integration.

Sameer Tikoo, GVP Communications & Network Provider Business Unit at GlobalLogic, emphasised the broader potential: “Private 5G networks are unlocking new opportunities for industries, from advanced automation to energy optimisation. Building on our partnership with Ericsson and working closely with the Hitachi Rail team, we are delivering ultra-reliable, low-latency, and secure wireless connectivity. 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.”

Why rail manufacturing needs digital acceleration

Rail remains central to the sustainable transport agenda, offering a low-emission, efficient mode of moving people and goods. Yet the industry has often lagged behind in adopting digital-first manufacturing processes. With rising demand for cleaner mobility solutions, the pressure is mounting to modernise production lines.

By embedding private 5G into its operations, Hitachi Rail is addressing key challenges:

• Global competitiveness: Digital-first production lowers costs, accelerates delivery, and enables North American rail to compete with international markets.

• Sustainability: Optimised systems reduce energy use and material waste, contributing to carbon reduction targets.

• Safety: Automation and real-time monitoring create safer working environments for factory employees.

The facility aligns with wider infrastructure investments across the United States, where government and private players are investing heavily in public transit expansion and rail modernisation. A factory capable of advanced, digitally enabled production is well positioned to supply this growing market.

The wider ecosystem of innovation

Hitachi Rail benefits from being part of the wider Hitachi Group, which combines expertise in IT, operational technology, and digital innovation. This synergy allows it to integrate AI, IoT, and data-driven tools into manufacturing and beyond. Hitachi Rail is also well known for its role in developing Japan’s famous bullet trains, a legacy it continues to evolve through global operations.

Ericsson’s contribution reflects its long history in telecommunications, stretching back nearly 150 years. Today, it continues to drive advancements in mobile connectivity, enterprise networking, and 5G infrastructure. For Ericsson, the Hagerstown project is a live case study of how private 5G can unlock industrial transformation in practice.

GlobalLogic, meanwhile, is at the forefront of digital engineering, helping clients across industries—from healthcare to media—embrace digital futures. Its integration expertise was critical to aligning complex systems within the Hagerstown factory.

A blueprint for the factories of tomorrow

The Hagerstown plant represents more than a single project. It demonstrates how rail and other manufacturing industries can future-proof themselves by embedding 5G-enabled systems at the heart of operations. With data-driven insights, predictive tools, and automation powered by private networks, industries can leap towards safer, smarter, and more sustainable production.

The project also underscores a broader trend: the convergence of telecoms, digital engineering, and industrial expertise. Partnerships like the one between GlobalLogic, Ericsson, and Hitachi Rail are shaping the new face of industrial manufacturing, where connectivity is no longer an add-on but the foundation.

As industries worldwide face pressure to meet net-zero goals, reduce operational risks, and respond quickly to market demands, private 5G networks are likely to become a standard feature in large-scale facilities.

At the cutting edge of Industry 4.0

Hitachi Rail’s investment in digital-first infrastructure is a bold move that will pay dividends far beyond Hagerstown. It’s a statement that rail manufacturing can be at the cutting edge of Industry 4.0, setting new benchmarks for efficiency, safety, and sustainability.

The blueprint established here will almost certainly inspire other industries to follow suit.