June 23, 2026
Latency Benchmarks for Private 5G Networks
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Deploying private 5G in assembly lines ensures reliable, low-latency connectivity for industrial operations, outperforming traditional Wi-Fi in challenging environments. Here’s what you need to know:
Private 5G networks are transforming industrial connectivity, enabling faster operations, reduced downtime, and better equipment efficiency. A structured approach ensures successful deployment within 12 weeks.
6-Step Process for Deploying Private 5G in Assembly Lines
Understanding your assembly line’s connectivity needs is the first step in shaping your network architecture, selecting hardware, and determining spectrum requirements. This involves defining specific connectivity goals, performing a detailed site survey, and mapping integration points.
Start by comparing your current performance metrics to industry benchmarks. For example, ensure latency remains below 20 ms and jitter stays under 5 ms – key factors for motion control and safety. High-definition quality control cameras typically need uplink bandwidths of 4–8 Mb/s per camera, and production halls often host anywhere from 100 to over 1,000 connected devices. For mission-critical operations, aim for network availability between 99.9% and 99.99%. Automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) require seamless handovers within 50 ms to maintain safety standards. To prioritise safety and command data, configure VLANs or APNs as early as possible.
Once these benchmarks are clear, move on to evaluating the physical environment.
A thorough site survey is essential for identifying any physical challenges that could impact connectivity. Factors like overhead cranes, forklifts, and other metal structures can create dead zones and cause jitter in traditional wireless networks. Understanding the layout and materials of your production space – such as hall geometry and steel density – will guide optimal access point placement. For instance, a production hall of 3,000–6,000 m² may need 1–2 indoor radios, while areas like heavy press or machining shops might require 2–6 radios.
Additionally, perform a spectrum check to identify available licensed or local spectrum. This helps avoid interference from unlicensed Wi-Fi airwaves. Don’t forget to account for the movement paths of assets like AGVs and verify spectrum availability before purchasing hardware. Some providers, such as Firecell, may even offer free site surveys and spectrum checks to help you get started.
Compile a list of all endpoints, including AGVs, AMRs, cobots, inspection robots, smart tools, and predictive maintenance sensors. Check which devices are already 5G-compatible and identify those that will need external routers or gateways. Don’t overlook legacy systems – map connectivity points like Programmable Logic Controller (PLC) gateways that link older machinery to your upgraded network. Finally, position edge servers near Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) systems to ensure the low-latency communication industrial automation demands.
Now, it’s time to design a network architecture that balances coverage, capacity, and reliability. This step includes choosing the right frequency bands, planning the placement of access points, and deciding on antenna configurations that suit your production environment.
The core network is the brain of your 5G setup, handling device authentication, session management, and data routing. Depending on your needs, you can choose between an on-premise core for greater control or a cloud-based core for easier integration with your IT systems and added flexibility.
In the USA, the Citizens Broadband Radio Service (CBRS) operates within the 3.5 GHz band (3,550–3,700 MHz), offering 150 MHz of bandwidth. You can either secure dedicated bandwidth with Priority Access Licences (PAL) or opt for shared usage via General Authorised Access (GAA).
For applications where every millisecond counts – like robotics or real-time sensor monitoring – ensure your core supports network slicing and traffic prioritisation. This allows you to dedicate bandwidth to critical processes. Adding edge computing hardware to your core architecture can also help by processing data closer to the production floor, cutting latency down to under 10 milliseconds. To avoid interference, an automated Spectrum Access System (SAS) can manage channel assignments, especially in environments with higher-tier users. These features are vital for seamless operations involving real-time robotics and sensor data.
Once the core is in place, the next focus is on optimising access point placement.
The placement of access points plays a key role in ensuring consistent coverage. Using small cells and Distributed Antenna Systems (DAS) can bring the network closer to users, improving both coverage and capacity.
Take into account the obstacles identified during your site survey. Position small cells strategically in any connectivity dead zones to maintain seamless coverage. Align the Radio Access Network (RAN) components with the physical layout of your facility and the expected density of devices. For larger spaces, DAS can extend coverage further. It’s also wise to plan for future expansion as more IoT devices and equipment are added over time.
Finally, make sure your access point placement works hand-in-hand with the chosen antenna configurations to maintain consistent signal quality.
Antenna configurations can significantly impact the performance of your network. Antennas with Massive MIMO (Multiple Input Multiple Output) technology are particularly effective in improving both capacity and coverage.
For example, in the USA’s CBRS band, indoor units (Category A) typically operate at 30 dBm/10 MHz to minimise interference in enclosed spaces. Outdoor units (Category B), on the other hand, can operate at 47 dBm/10 MHz to cover larger areas.
To ensure consistent coverage, consider using coordinated redundancy with multiple access points. This approach also helps minimise interference. Keep in mind that changes to the factory floor can affect signal strength, so it’s a good idea to re-test performance whenever modifications are made. Adjust power levels as needed to manage interference and comply with regulations, keeping your network adaptable as your production line evolves.
Once your network architecture is mapped out, the next step is acquiring the right hardware and software. The aim is to select tools that not only meet your current requirements but also allow for growth without needing to start from scratch.
Turnkey solutions can simplify the deployment process significantly. Look for systems that integrate smoothly with your existing enterprise LAN, ideally using DHCP for IP allocation, much like Wi-Fi does. This approach removes the need for deep telecom expertise.
For testing and development, pre-configured lab kits are a great starting point. Take Firecell’s Orion Labkit as an example – it costs €11,900 upfront with an annual fee of €5,580. This kit can cover areas ranging from 10m² to 1,000m² with a single 5G access point and supports O-RAN for added flexibility.
Dr. Richard Candell, Leader of the Industrial Wireless Systems Project at NIST, remarked: "Having full visibility on the core and radio access network (RAN) and their different interfaces is unique and one of the key factors behind NIST choosing Firecell’s Labkit".
When evaluating solutions, prioritise cloud-native core networks that support Network Functions Virtualisation (NFV). This setup allows for efficient resource allocation and quick deployment of new services as your production line evolves. If you’re planning larger deployments covering over 10,000m², scalable options like the Pegasus Network, which supports up to 10 access points, can be a solid choice while maintaining the same architectural structure.
The next step is to ensure all devices on your assembly line meet the necessary technical specifications.
After selecting your turnkey solution, it’s crucial to verify that all connected devices are compatible with your network. User equipment, such as scanners, programmable logic controllers (PLCs), and automated guided vehicles (AGVs), must support your chosen frequency bands and protocols. Pre-validating these devices can save you from integration headaches later.
For environments with a high density of devices, consider hardware that supports Massive MIMO (Multiple Input Multiple Output) technology to increase signal capacity and coverage. If you’re deploying in the USA and using the CBRS spectrum, ensure that your radio units are FCC-certified for the 3.5 GHz band and work with Spectrum Access System (SAS) providers. For better security, opt for devices that use SIM or eSIM-based authentication instead of shared passwords. This approach simplifies both device management and security audits as your network grows.
Once device compatibility is confirmed, think ahead to support seamless growth. Modular components are a smart choice, as they allow for incremental scaling. For example, a single indoor 5G radio can cover between 3,000 and 6,000m², meaning you can expand or rearrange your factory without needing extensive new cabling. Additionally, 5G access points tend to have a longer lifespan compared to Wi-Fi equipment.
To support real-time data processing, consider adding edge computing hardware like servers and storage units. This setup ensures latency stays under 20ms, which is critical for applications like autonomous robotics and machine vision. The flexibility of 5G also reduces reliance on fixed Ethernet infrastructure, giving you the freedom to adapt your assembly line as needed.
Step 4 moves you from planning and purchasing to the actual setup and integration of your network, bringing your assembly line closer to being fully operational. With the hardware in hand, it’s time to install the equipment, link it to your existing systems, and fine-tune the network for top performance.
Start by mounting your 5G RAN components in the locations identified during the site survey. Proper positioning is critical, especially in industrial settings with obstacles like moving machinery, cranes, and steel structures that can disrupt radio signals. For heavily obstructed areas, such as press shops, you may need 2–6 radios to counteract signal interference caused by dense steel.
Ensure all equipment is built to withstand harsh industrial conditions, such as vibration and dust. Look for hardware with an IP67 rating, which is designed for durability in challenging environments. Place edge servers close to your Manufacturing Execution Systems (MES) or ERP systems to enable real-time data processing and maintain latency at under 20ms for smooth control loops. For areas with poor signal coverage, deploy small cells or a Distributed Antenna System (DAS) to eliminate dead spots. Once everything is securely installed and tested, integrate the hardware into your existing network.
After installation, the next step is integrating the new components into your enterprise network. Firecell’s solutions are designed to integrate effortlessly with your existing enterprise LAN, functioning as a natural extension of your network. Configure the 5G system to use your enterprise DHCP for UE IP allocation. This approach allows your IT team to manage 5G devices like any other network asset, removing the need for telecom-specific expertise.
Set up VLAN or Access Point Name (APN) configurations to separate traffic types – such as management, production, and guest traffic – ensuring critical data streams remain isolated and automation systems remain stable. Connect the 5G core to your operational technology systems, including MES, Warehouse Management Systems (WMS), ERP, and SCADA, to ensure seamless integration.
With hardware installed and integrated, the final step is setting up key network features. Apply deterministic QoS to prioritise automation traffic over less critical data streams. Use priority-based scheduling to maintain stable performance for essential applications, even during peak usage.
Implement network slicing to separate different device types and data streams. For example, allocate uplink capacity – typically 4–8 Mb/s per HD camera – to support machine vision and quality control processes. Strengthen security by configuring SIM or eSIM-based authentication and encryption. Additionally, ensure handovers between cells occur in under 50ms to support mobile robots and AGVs moving along the assembly line.
Set a network availability target of 99.9% to 99.99% during production hours, with round-trip latency kept below 20ms and jitter under 5ms for consistent control. From the delivery of hardware to final acceptance testing, a full site deployment typically takes around 12 weeks.
Thoroughly evaluate your 5G network’s performance through lab testing, on-site validation, and parameter adjustments to avoid costly interruptions during deployment.
Start by using Firecell’s lab kits to test device compatibility and core functionality. Perform stress tests under simulated conditions to ensure the network can handle various industrial devices – like sensors, AGVs, and handheld scanners – while operating within its designated frequency bands and protocols. These tests should include SIM or eSIM provisioning to confirm stability and performance. Key performance indicators (KPIs), such as sub-20ms latency and under-5ms jitter, must be met during these trials.
Evaluate Quality of Service (QoS) to ensure critical data traffic, such as safety loops and motion control, takes precedence over less urgent streams like background telemetry. Security assessments are equally important – verify encryption and network slicing are functioning as expected. Additionally, measure performance against industrial benchmarks: round-trip latency should remain under 20ms, jitter below 5ms, and handovers between network cells should complete in less than 50ms, particularly for mobile robots and cobots.
After lab testing, transition to Site Acceptance Testing on the actual assembly line. Test the network’s end-to-end performance when integrated with your enterprise LAN. This includes functional upload and download tests, round-trip latency measurements, and over-the-air RF spectrum analysis to check signal parameters like PCI, SSB, and SIB. Regularly monitor signal propagation as the factory floor layout changes due to moving equipment, paying close attention to coverage, throughput, and latency.
For precise validation, use the Two-Way Active Measurement Protocol (TWAMP) instead of standard pings to measure latency and packet delay variation. Synchronise sender and receiver devices with GPS-locked PPS to accurately measure one-way latency. Deploy RF probes on AGVs and AMRs to autonomously test connectivity and latency as they navigate the assembly line. Ensure the network performs reliably in high-density environments – handling 100 to over 1,000 devices per hall – and in challenging RF conditions, such as those found in press shops or machining areas with moving metal.
Use Firecell’s network management interface to monitor KPIs and adjust settings like beamforming, power levels, and interference management to maintain an availability target of 99.9% to 99.99% during production. Leverage deterministic QoS to prioritise critical applications, ensuring stability even under heavy network loads.
Fine-tune VLAN or APN configurations to separate essential assembly line operations from less critical data streams. Measure metrics such as Signal-to-Interference-plus-Noise Ratio (SINR) and Reference Signal Received Power (RSRP) to identify and resolve performance issues. Optimise speed, latency, and capacity based on test outcomes, and position edge servers close to MES/ERP systems to maintain sub-20ms control loops. These steps are essential for a smooth transition to the controlled go-live phase in Step 6.
Transitioning your validated 5G network into full production requires a carefully planned rollout to minimise disruptions and ensure reliability across your assembly operations.
Start with a pilot deployment on a single assembly line or a specific cell. This helps validate the concept before expanding across the entire plant. During this phase, integrate the 5G core with your existing enterprise systems – like MES, WMS, and ERP – and hardware such as AGVs or PLCs. Follow this with acceptance testing to confirm the network meets industrial standards for robot fleets and assembly tools.
Before going live, conduct stress tests, security assessments, and Quality of Service checks. Replace shared device credentials with per-device SIM or eSIM security for improved safety. Ensure your IT teams are trained on Firecell’s Network Monitoring Interface, allowing them to manage the system independently or through managed services. From hardware delivery to acceptance testing, a full site rollout typically takes about 12 weeks. This phased approach ensures a seamless transition to continuous network monitoring.
After successful tests, deploy data probes across fixed and mobile assets, such as AGVs and AMRs, to monitor the network 24/7 throughout the year. Keep an eye on KPIs like availability, throughput, latency, and handover times. Be mindful of physical changes on the factory floor – moving metal shelves or robots can impact signal propagation, so regular performance checks are crucial. Use TWAMP instead of standard pings to verify low-latency requirements for applications like robot control. Additionally, monitor SINR and perform periodic RF spectrum analysis to ensure the environment remains free from interference.
Once the network is optimised (as outlined in Step 5), regular upkeep is key to maintaining peak performance. Schedule audits to fine-tune network parameters and update software and firmware, ensuring the system operates at optimal speed, latency, and capacity. Continuous monitoring supports predictive maintenance, helping you identify and resolve anomalies before they become major problems.
Firecell offers post-delivery support, including online and on-site assistance, along with periodic network upgrades. The durability of 5G infrastructure also reduces overhaul costs compared to Wi-Fi. By designing your wireless network to be easily reconfigurable, you can adapt quickly to new models and production lines, avoiding the delays often associated with cable reconfiguration. This flexibility ensures you maintain the sub-20 ms control loops critical for assembly line operations.
Setting up private 5G networks for assembly lines demands careful planning, precise hardware selection, and rigorous testing to ensure the low-latency, reliable connectivity essential for modern manufacturing. Conducting thorough site surveys helps uncover potential RF challenges in demanding industrial settings, while choosing the right frequency bands and configuring access points allows for seamless support of 100 to over 1,000 SIM-based devices in a single production hall.
The advantages are clear. These networks enable improvements like quicker automated mobility, shorter changeover times, and better equipment efficiency.
Firecell offers a streamlined solution, making complex telecom deployments manageable for standard IT teams without requiring specialised telecom knowledge. Their structured 12-week roadmap – from radio planning to full site activation – ensures predictable timelines. For instance, in an automotive plant with 20 automated forklifts, a Firecell 5G network costing £200,000 delivered a return on investment within 10 months by cutting downtime and boosting throughput. This example highlights the importance of a step-by-step deployment process.
The formula for success involves a systematic approach: thoroughly assess needs, design for industrial-grade performance, select compatible hardware, integrate smoothly with existing systems, and perform comprehensive testing before launch. With careful planning and the right partner, private 5G can revolutionise assembly line operations, providing secure, reliable, and adaptable connectivity to meet evolving production demands.
To set up a private 5G network in a UK factory, you’ll need a spectrum licence from Ofcom. Here are the available options:
Make sure to review Ofcom’s guidelines carefully to ensure compliance and obtain the correct licence for your requirements.
The number of 5G radios you’ll need depends on the size, layout, and coverage needs of your assembly hall. Unlike Wi-Fi, private 5G networks often require far fewer access points. For a large hall, placing just a few radios in key locations can provide comprehensive coverage and reliable connections, even in high-traffic or critical areas. To get it right, conduct a site survey and reach out to Firecell for customised deployment advice.
Your current AGVs, PLCs, and cameras might need updates to work seamlessly with a 5G network. Devices built with older wireless standards or those using wired connections could require hardware or firmware upgrades to align with 5G technology. This is especially crucial in challenging environments – like areas with metallic structures or intricate layouts – where connectivity issues and interference can hinder performance.
