Manufacturing

Revolutionizing Factory Floor Connectivity

SEW, a global leader in drive systems and a family-owned German company, specializes in providing gearmotors, variable speed drives, and automation components. With 22,000 employees and 17 production plants worldwide, SEW-EURODRIVE is at the forefront of industrial innovation, particularly in its 4.0 factory in Brumath, France. This advanced facility relies heavily on Automated Guided Vehicles (AGVs) for autonomous material transport, adhering to strict safety standards and automating tasks, especially at the end of the production line.

However, SEW faced significant challenges with its existing wireless infrastructure. Michel de Hatten, Head of IT at SEW, noted, "Previously, our biggest Wi-Fi challenge was seamless roaming." The standard Wi-Fi solution, while latest generation, experienced service disruptions during AGV roaming between stations, and bandwidth was limited by the number of concurrent Wi-Fi users. These issues, common in dynamic factory environments with constantly changing layouts and RF interference, led to dropped connections, potential line stops, safety concerns, and a loss of productivity. The need for mobile, reliable, and lossless wireless connectivity across the entire process became critical as SEW looked to expand its use of advanced robotics and prepare for future video and AI applications.

Unified Platform for Uninterrupted Operations

SEW did a proof of concept to try out Cisco Wireless with URWB, a unified platform that integrates traditional Wi-Fi with Ultra-Reliable Wireless Backhaul (URWB). This solution offered a unique opportunity to reduce costs and complexity while significantly increasing the efficiency of wireless coverage across both office and manufacturing areas.

The deployment was remarkably swift. Michel de Hatten reported, "The Cisco solution was relatively easy to deploy. We were impressed by how quickly it was deployed—within just a few days, both the controllers and access points were operational." The most significant benefit was a dramatic improvement in wireless coverage, allowing SEW to reduce the number of access points by nearly half while improving overall performance.

Franck Bonnard, IT/OT Convergence Consultant at NXO, who supported the project, highlighted two major advancements: "First, we enabled message duplication between AGVs and the network edge across multiple access points—significantly boosting performance and availability. This helped overcome interference and obstacles that are common in dynamic manufacturing environments, ensuring mobile robots maintain uninterrupted connectivity. Second, Cisco’s access points now allow us to operate Wi-Fi simultaneously with URWB required for AGVs within a single, unified system." 

Driving Efficiency and Future Innovation

The Cisco Wireless with URWB has delivered substantial benefits for SEW. The enhanced wireless coverage and seamless roaming capabilities mean that AGVs can now operate without interruption, even in motion, directly impacting productivity and safety on the factory floor. The ability to reduce the number of access points by nearly half while improving performance represents significant cost savings and simplified network management.

The IT-OT convergence enabled by the unified platform is a gamechanger for SEW. Managing both environments from a single pane of glass, via Wireless LAN Controller (WLC) and Cisco Catalyst Center, streamlines operations and reduces complexity.

With ultra-reliable connectivity supporting PLC communications and industrial safety protocols, SEW's factory is now better equipped for the demands of Industry 4.0. The future-proof technology, supporting upcoming bandwidth needs for video and AI applications, positions SEW to continue its innovation in advanced robotics and automation, ensuring sustained growth and operational excellence.