Local 5G and Digital Twin Utilization: Factory Layout Simulation Effectiveness Demonstrated from a Field Perspective

BeRise Inc. (hereinafter, "our company"), a system developer specializing in cutting-edge technologies such as XR (VR/AR/MR), has developed a "Factory Layout Simulator" utilizing digital twins at a factory operated by Toshiba Corporation (hereinafter, "Toshiba"), and has commenced a demonstration operation incorporating feedback from the field. This project focuses on practical system implementation for actual field operations, including management of operation schedules, automatic calculation of space utilization rates, and ensuring safety space for workers.

This project was launched as part of "Tokyo NEXT 5G," a project promoted by the Tokyo Metropolitan Government for the social implementation and dissemination of local 5G technology, with the support of Plug and Play Japan Inc., the development promoter.

1. Development Background

Our company is developing "Genba AI" (Field AI), a business support system tailored to the field, to address challenges in Japan's manufacturing industry such as labor shortages and technology transfer. We are also working towards a future where field support is possible from remote locations by consolidating know-how from Genba AI and records of field workers onto a digital twin.

When realizing a future where each field worker is connected to AI and data is aggregated on a digital twin serving as a data foundation, the load on communication infrastructure becomes a challenge. This project focused on local 5G technology, which offers strengths such as massive machine-type communications (mMTC), high security, and low latency, and conducted a demonstration experiment connecting and operating a factory digital twin, which will serve as a future data foundation, with local 5G as the communication infrastructure.

This project was launched as part of "Tokyo NEXT 5G," a project promoted by the Tokyo Metropolitan Government for the social implementation and dissemination of local 5G technology, with the support of Plug and Play Japan Inc., the development promoter.

By utilizing subsidies from the Tokyo Metropolitan Government and receiving factory space from Toshiba as a demonstration field, we have established a robust development and demonstration framework through industry-government collaboration.

2. Features of the Factory Layout Simulator and Objectives of the Demonstration Experiment

A 3D preview of the Toshiba factory constructed from scan data.

The "Factory Layout Simulator" system has undergone revisions and functional implementations based on feedback from the field to directly contribute to continuous operational improvements in actual factory settings. The objective of this demonstration experiment was to verify whether large-capacity spatial data and layout data could be communicated under a local 5G environment.

3D preview screen.

UI/UX Improvements and Flexibility Reflecting Field Voices

We have made detailed adjustments to ensure that field workers can use operations such as 3D space manipulation, layout adjustments, and schedule management without stress.

Simulation Functions Directly Linked to Practical Work (Safety Checks, Grouping, etc.)

In addition to asset placement (2D/3D linkage) of fixtures, etc., it is equipped with a function to set and display "personnel work areas." This allows for pre-verification in a virtual space not just of object placement, but also of whether safe working space is secured.

Floor plan.

Visualizing not only fixture placement but also worker safety space (personnel work areas).

Calendar-style main screen.

Automatic Calculation of Space Utilization (Operation Rate) and Schedule Management

The calendar-style main screen automatically calculates and displays the "operation rate (%)" for each area. By linking production management information such as manufacturing area name, operation period, customer name, and manufacturing model number with the layout, layout simulations can be performed based on objective data.

The Key to Local 5G with an Eye on the Future

Furthermore, this demonstration experiment also considers the future scalability of factories. As digitalization progresses, it is expected that the standard working style will involve all field workers wearing wearable devices such as smart glasses to receive work support. Considering a situation where a mechanism to reflect vast amounts of video and log data from each device onto this digital twin in real-time becomes essential, we believe local 5G will be key to simultaneously advancing quality maintenance and efficiency.

3. "Local 5G" Accelerating Digital Twins

Source: Toshiba Corporation Official Website (https://www.global.toshiba.jp/jp/products-solutions/social/telecommunication/local5g.html)

In this project, it was necessary to effectively utilize the functions of digital twins while paying attention to factory-specific challenges such as handling large-capacity data and maintaining security. Therefore, local 5G, a next-generation infrastructure, was adopted as the foundation for this system.

Massive Machine-Type Communications (mMTC)

Considering a future where all field workers access AI from wearable devices and PCs, and their data is stored on the digital twin, a communication infrastructure capable of handling massive machine-type communications is necessary for users to utilize it without stress.

Ensuring High Security

Factory layout and production line data are top-secret. By using local 5G, which is a closed network, we are realizing secure data storage by blocking the risk of information leakage to the outside.

Low Latency

Robots and cameras operating in the field require large-capacity, real-time information communication. If these are compromised, it can lead to decreased product productivity or prolonged recovery times from failures, resulting in corporate losses. Therefore, a stable communication environment with low latency is necessary.

4. Future Prospects

This system aims to be a system that can analyze hidden issues in the field that were not apparent with traditional Excel-based field management, and we will continue to verify it. Furthermore, we are considering the implementation of a function to equip robots with cameras to automatically patrol the factory and update obstacles and daily changes on the digital twin in real-time.

The foundation of this initiative is Genba AI provided by BeRise. With the concept of creating an environment where the field can concentrate on its core operations and maximizing human capabilities, it solves field challenges from two main aspects:

* Improving spatial utilization and work time efficiency By displaying information in space and having AI handle record-keeping, it eliminates the effort of "preparation, input, and search." * Internalizing technology resources Through AR guidance and AI decision support, it shortens the training period for new employees and prevents the "reinventing the wheel" of skills held by experienced workers.

Starting with the practical operation of digital twins in a local 5G environment, we will support DX promotion in all industries that require advanced spatial management, not limited to manufacturing, but also including construction sites, facility management/security, logistics warehouses, smart buildings, and infrastructure facilities.

5. Contact Information

BeRise Inc.

Contact Person: Morishita, Planning and Development Department

E-mail: [email protected]

TEL: 082-264-2600