Client Context
A tier-one automotive parts manufacturer operating a 640,000 sq. ft. production plant in the Southeast, running a growing fleet of automated guided vehicles (AGVs) alongside traditional line equipment. Client details are shared with permission in anonymized form.
The Problem
The plant's Wi-Fi network, originally designed for handheld scanners and office connectivity, was struggling under a fast-growing AGV fleet. As vehicles moved between access point coverage zones, session handoffs frequently failed — causing AGVs to stop in place until connectivity re-established. Each stoppage rippled into the production line behind it.
Our Approach
We began with an RF survey across the full production floor, mapping existing Wi-Fi coverage against actual AGV routes and dwell times rather than static device locations.
The data showed the handoff failures weren't a coverage problem — they were an architecture problem. Wi-Fi's connection model wasn't suited to the volume and speed of roaming the AGV fleet required.
We designed a private CBRS LTE network sized for the full AGV fleet plus headroom for planned expansion, handled SAS spectrum coordination, and ran a vendor-neutral hardware evaluation before recommending a radio and core vendor. Deployment was phased by production zone to avoid a full-line shutdown.
The Outcome
Following cutover, AGV connectivity-related stoppages dropped 82% in the first full production month. The entire AGV fleet now operates on the private LTE network, with the legacy Wi-Fi network freed up for handheld scanning and general connectivity — the workload it was originally sized for.
Private 5G & LTE Design
This engagement was delivered as part of our Private 5G & LTE Design service.
See the service