Can Manufacturing Truly Go Wireless in a 5G/Wi‑Fi 6 Era?

Recent deployments of Wi‑Fi 6, early 5G pilots, and evolving shared‑license spectrum rules have sparked a key question: can manufacturing embrace a fully wireless future? The short answer is yes; the long answer is a complex mix of timing, technical requirements, and cost considerations.

Manufacturing equipment is built for 10‑15 year lifecycles, and roughly 80 % of current factory connectivity remains wired. While Wi‑Fi 6 offers backward compatibility and a smoother upgrade path, 5G is not a plug‑and‑play solution. 5G roll‑outs will unfold gradually as existing hardware is refreshed or replaced, and dedicated factory‑grade 5G user equipment is still nascent as standards mature.

Key use cases that drive wireless adoption include a mobile workforce, remote expert systems tied to secure plant equipment, workforce and asset location tracking, wireless machine instrumentation, autonomous vehicles, mobile machines, physical security, workflow optimization, and wireless sensification. Emerging applications will likely extend to robotics, AR/VR, and digital twins.

These scenarios demand different levels of determinism, latency, and throughput. Low‑latency requirements—traditionally the realm of wired IEEE 802.1Q Time‑Sensitive Networking (TSN)—are now a central focus for wireless. 5G Ultra‑Reliable Low‑Latency Communication (URLLC) targets 1‑10 ms end‑to‑end latency, with 1 ms being especially challenging for radio. Standards bodies such as 3GPP and 5G‑ACIA are actively pursuing these capabilities.

Geography matters. Top industrial nations are progressively allocating dedicated spectrum blocks to support vertical‑specific needs. For example, in Germany, companies can bid for private LTE/5G spectrum in 10 MHz blocks with 10‑year licenses and renewal options. A prominent German automaker recently announced that it will operate its own 5G network on the factory floor, giving operators full control or the choice to engage a service provider.

In the U.S., the Citizens Band Radio System (CBRS) offers a shared spectrum model with three tiers—Incumbents, Priority Access Licenses (PALs), and General Authorized Access (GAA). Because CBRS is shared, GAA users may experience interruptions from incumbents (e.g., the U.S. Navy) or PAL holders. Deploying a 5G network on CBRS also requires investment in new radio nodes, NICs, and end‑equipment adapters.

Deciding when to deploy wireless hinges on the specific use cases, network performance needs, and the availability of spectrum or service‑provider plans that can guarantee the required quality of service (QoS). Each factory must assess whether a dedicated spectrum “slice” or a shared band best aligns with its objectives.

For most manufacturers, a multi‑access strategy that blends wired, Bluetooth, LoRa, Wi‑Fi, Wi‑Fi 6, LTE, and 5G will deliver the most resilience and flexibility. Such an approach allows the selection of the most appropriate technology for each application while maintaining overall operational continuity.

Build or Buy?

The classic build‑versus‑buy dilemma reappears when deciding how to introduce 5G. Should a company secure its own spectrum and build a private network, or partner with a carrier that offers a dedicated “slice” and manages the deployment and operations? Building gives maximum control but demands a steep learning curve, ongoing maintenance, higher upfront costs for dedicated equipment, and potentially slower access to the latest features. Outsourcing delivers cutting‑edge technology and reduces day‑to‑day management burdens, at the expense of some control.

Ultimately, the optimal strategy will reflect the intended use cases. A hybrid model—leveraging a multi‑access environment combined with a tailored 5G deployment—often delivers the best balance of cost, control, and performance.

Costs to Consider

Investing in Wi‑Fi 6 and 5G can create a “which comes first?” dilemma. With factory floors still dominated by hard‑wired machinery, retrofitting to wireless can be costly and disruptive. Conversely, the benefits of 5G may be under‑realized if the equipment cannot fully exploit the technology. Manufacturers need a long‑term roadmap that phases upgrades, balances investment against expected returns, and aligns with the evolving wireless ecosystem.

At Cisco, we guide customers through a constantly evolving roadmap that ensures network investments remain safe and future‑ready—from today’s wired fabric to tomorrow’s 5G and beyond—unlocking greater operational value along the way.

For deeper insight into wireless trends and adoption stages, download our white paper, Wi‑Fi 6 and Private LTE/5G Technology and Business Models in Industrial IoT, or read the Executive Summary for a concise overview.