Background

Production facilities are more and more embedded in digital networks, and this trend is gaining momentum. Such networked systems offer several benefits:

Manufacturing processes can be monitored and controlled more effectively, and Manufacturing Execution Systems (MES) enable production planning in the office while coordinating operations on the shop floor. They collect production data and support the remote analysis and maintenance of equipment. Moreover, machine and sensor data pave the way for predictive maintenance, enabling problems to be detected at an early stage—before failures occur. Maintenance activities can be planned more efficiently, thereby reducing downtime.

Cloud-based MES represents the next step in development. Storing and providing data via cloud services makes it easier to manage multiple sites, perform updates centrally, and deploy new services. It also enables new business models such as Equipment as a Service (EaaS), where machines are not purchased but used on a service basis. Therefore, companies can avoid high upfront costs while still gaining access to modern and efficient technology.

Cloud-based MES and EaaS rely on a fast, secure, and stable internet connection. 5G provides this and is also flexible and scalable. With 5G as a foundation, machine fleets can be networked across locations without requiring extensive local IT infrastructure. This presents a significant advantage for small businesses that cannot afford expensive equipment.

However, networked systems also entail increased risks of cyberattacks. Therefore, a comprehensive security concept is required, integrated into the system from the outset (“security by design”).

Project Content

DREAM 5G lays the groundwork for secure 5G communication in networked machine fleets, enabling reliable EaaS operations. This includes:

• Scalable 5G connectivity that grows with machine fleets and company size.
• Security by design, including measures to increase resilience against common disruption and attack scenarios in 5G environments (e.g. DDoS, ransomware, insider threats).
• AI-supported maintenance, including data pipelines and models that detect maintenance needs at an early stage and, where possible, provide actionable recommendations. This also involves visualisations that make it easier to identify problems and develop appropriate responses.

The project relies on the expertise of both industry and research partners: CIDAN contributes machine integration and service processes (software/connected services), SAL develops and validates the 5G/edge communication solution, ISF (USTP) is responsible for security and resilience testing, and ICMT (USTP) develops operational data analytics and user‑centred dashboard design.

Results and Benefits

5G connectivity links machines to digital service chains in a controlled manner and prevents local IT systems from becoming a bottleneck. Security‑by‑design, access controls, and clear system separation enhance communication security. At the same time, remote access for diagnostics, updates, and maintenance becomes more reliable. Resilience measures help detect and contain disruptions and attacks. The result is reduced machine downtime.

Partner

Funding