With ultra-fast speeds and near-instantaneous response times, 5G technology is bringing automotive production into the digital age by enhancing its manufacturing operations. At Hyundai Motor Group Innovation Center in Singapore (HMGICS), this next-generation connectivity is powering 60 mobile robots to enable agile, customer-centric vehicle production.
This hub will redefine future mobility production and customer experience by integrating Industry 4.0 technologies for a consumer-oriented manufacturing, with the goal of enhancing EV ownership.
With IMDA's 5G Innovation Programme, HMGICS is now equipped with high-speed connectivity and massive bandwidth for the robots to have high-precision quality control and ability to enable such technologies, establishing new benchmarks for efficiency and customisation in the automotive industry.
Transforming Automotive Manufacturing Through 5G Innovation
To realize its vision of a smart urban mobility hub, HMGICS has implemented two groundbreaking use cases that showcase the true potential of 5G technology:
1. Autonomous Mobile Robots (AMR) for Logistics
The fleet of AMRs enable enhanced logistics operations through real-time coordination. Mobile robots receive commands from the AMR control system (ACS) to locate the specific car components for the assembly and delivery them precisely to their designated assembly points.
The robots employ advanced collision prevention and obstacle avoidance capabilities, continuously monitoring their environment through sophisticated sensors. When obstacles are detected, the robots automatically slow down, navigate around them, or stop completely if necessary, ensuring safe operations in the dynamic factory environment.
Real-time coordination between multiple robots is achieved through the 5G network's ultra-low latency, enabling smooth traffic management and optimal routing across the facility. This coordinated movement is essential for maintaining efficient production flow in the flexible cell manufacturing system.
"The 5G enabled robots are critical to support the development of these vehicles through low latency, high reliability and increased speed of 5G networks for the smart assembly production such as logistics part delivery to enable the car body assembly and chassis assembly,” said the project team.
2. Autonomous Guided Vehicles (AGV) for Chassis Assembly
The facility's 5G-enabled Automated Guided Vehicles (AGVs) perform two distinct functions in the assembly process:
First, the Body AGV transports the vehicle's outer shell to the chassis assembly starting point. Then, the Chassis AGV delivers the battery pack to the assembly station. After the chassis is fully assembled with the battery pack, the same Chassis AGV moves the completed unit to the storage area.
The fleet of AGVs manage the complex choreography of moving vehicles – from maintaining continuous communication with the control system, providing real-time updates on position and status, to enabling dynamic adjustment of routes and timing, optimising production flow. Additionally, the AGVs handle critical components like battery packs with exceptional accuracy, moving them from lifters through chassis sub-module cells and to storage areas before final chassis marriage, demonstrates the precision and reliability enabled by 5G connectivity.
Measurable Impact and Benefits
HMGICS's 5G implementation has delivered remarkable results:
Production Excellence
- Successfully manufactured 477 Built-To-Order (BTO) vehicles during the sustainability period
- Spanning three distinct EV models: IONIQ 5, IONIQ 5 'Robotaxi', and IONIQ 6
- Achieved zero safety incidents throughout the implementation period, validating the effectiveness of the collision prevention and obstacle avoidance systems implemented in the 5G-enabled robots
Technical Performance
The 5G network demonstrated superior performance compared to WiFi across all key metrics:
Network Speed and Responsiveness:
- Average latency of 18.5ms, representing an 85% reduction compared to WiFi's average of 96.3ms
- Maximum latency capped at 80ms on 5G, dramatically outperforming WiFi's peak of 975ms
Network Reliability:
- Improved network reliability with less than 1% packet loss versus WiFi's 30%
- Consistent performance even under network congestion, ensuring uninterrupted operations during peak production periods
Operational Efficiency
The technical improvements directly translated to operational benefits:
Automation and Coordination:
- Seamless coordination among 60 5G-enabled AMRs on the across the 280m x 100m assembly floor facility
- High level of automation (more than 50% efficiency improvements) provided enhanced flexibility for high-mix, low-volume production
Workplace Enhancement:
- Reduced manual material handling operations by over 50%, therefore improving workplace safety through automated heavy lifting and transport
- Enabled workers to focus on higher-value tasks requiring human expertise
Driving Innovation Through IMDA's Support
IMDA's 5G Innovation Programme has been instrumental in making this transformation possible. The initiative supported HMGICS in:
- Testing and implementing 5G solutions in a live manufacturing environment
- Developing commercial applications of 5G technology
- Driving industry transformation
Through this implementation, IMDA has helped strengthen Singapore's position as a manufacturing innovation hub, showcasing the country's capabilities in advanced manufacturing and digital transformation.
Building the Future of Automotive Manufacturing
HMGICS's implementation opens new possibilities for the automotive sector. Future plans include:
- Implementing EV mobile robot charging solutions
- Integrating 5G-enabled PLC for overhead hangar systems
- Deploying AI inspection applications with Boston Dynamics SPOT robots
- Expanding 5G connectivity for maintenance applications
"HMGICS has assembled more than 1,000 vehicles and will continue to grow towards a sustainable future of Singapore," notes the project team, "by combining Hyundai's manufacturing expertise and the latest cutting-edge technologies, seeking progress for humanity to create a new paradigm of smart manufacturing."
Shaping Singapore's Automotive Manufacturing Future
With 5G technology enabling unprecedented levels of automation and flexibility, HMGICS demonstrates how advanced connectivity can transform traditional manufacturing into customer-oriented, flexible production systems. Whether as a technology provider, manufacturer, or industry leader looking to leverage 5G, Singapore's digital transformation journey offers unprecedented opportunities.
By combining advanced connectivity with innovative manufacturing processes, HMGICS is not just building cars – it's helping to shape the future of manufacturing in Singapore and beyond.
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