5G smart production lines boost bicycle manufacturing

microSHIFT, in partnership with the Taiwan Smart Electric Bicycle Association (TSEBA), recently hosted a presentation on the 5G smart production lines they’d deployed, at the Taichung GIS Convention Centre. The event saw participation from key industry players, including FlexLink, Inventec, and NewWave, alongside numerous bicycle supply chain manufacturers from Central Taiwan.

Since 2023, the Administration for Digital Industries under the Ministry of Digital Affairs (moda) has been actively collaborating with public associations to advance the development and application of 5G private networks across various sectors. The goal is to enhance industrial competitiveness through technological innovation.

Moda supports these efforts by implementing relevant policies, fostering industry-academia collaboration, and providing financial and technical assistance. This comprehensive approach facilitates the rapid integration of 5G technology, accelerating industry upgrades and transformation. Under the guidance of the Digital Industries Administration, microSHIFT has teamed up with FlexLink, Inventec, and NewWave to explore 5G applications through the ‘5G Innovative Application Project,’ speeding up the journey towards smart manufacturing.

The synergy of 5G and AI offers transformative potential for the manufacturing sector, driving industry upgrades and innovation.

 “5G smart factories can address the issue of labour shortages in manufacturing. The online and offline integrated production model allows for the real-time collection of various production data. This enables flexible production with small-batch and diverse options and utilises AI for analysis to further optimize production efficiency and yield,” said Thompson Su, Secretary General, TSEBA. “It achieves cost and performance optimisation for smart factories and can eventually evolve into an AI production platform and manufacturing base. microSHIFT completion of the 5G smart production line innovative application project serves as a model. We hope that all association members can upgrade intelligently, enhance their competitiveness, and continue to thrive in Taiwan, becoming the top outstanding enterprises in Taiwan.”

Established 25 years ago, microSHIFT is a manufacturer of bicycle gear systems, serving major markets in North America, Europe, Central and South America, and Asia. The company’s clients include renowned bicycle brands such as Decathlon, Giant, and Merida. microSHIFT operates manufacturing facilities in China, a research and development centre, and a manufacturing base for high-end products in Taiwan, as well as a brand and market development centre in the United States.

Smart manufacturing enables flexible production, optimises efficiency, and enhances business resilience.

William Chen, CEO of microSHIFT said: “Considering the trends in 5G smart manufacturing and AI, we saw an opportunity to initiate our digital transformation project. microSHIFT is the first domestic company to participate in the government’s 5G Dedicated Network Innovative Application Diffusion Project and has successfully established a 5G smart production line for bicycle gear systems. We have completed the deployment of 5G dedicated network equipment, including applications such as a Manufacturing Execution System (MES), Internet of Things (IoT), Advanced Planning and Scheduling (APS), and real-time equipment health prediction and diagnostics. Additionally, we have addressed 5G network security planning and safety verification.”

Chen detailed the application of these technologies in the CNC processing area, where 5G equipment and two small base stations have been installed. With support from Inventec, 33 CNC and plastic injection machines have been networked, and equipment health prediction diagnostics have been implemented. Leveraging the large bandwidth, low latency, and multi-connectivity features of the 5G private network, real-time data is captured, and a tool wear database is established.

AI-trained predictive models issue warnings before tool failures occur, preventing defective production and minimising operational inefficiencies. Furthermore, the mobile reporting system, powered by 5G, significantly reduces the time previously spent on paper-based processes and lowers error rates. The returned information is integrated with Siemens’ smart scheduling system, OPCENTER, enabling real-time, flexible adjustments to work orders and improving order fulfilment rates.

By capitalising on the extensive bandwidth, low latency, and multiple connections offered by the 5G private network, microSHIFT has implemented diverse applications such as MES, IoT, APS, and real-time equipment health diagnostics. These advancements have enhanced production efficiency and management effectiveness.

Delivery lead times have been shortened by 15 days, order fulfilment rates have increased by 10%, material availability rates have improved by 10%, and CNC machine utilisation rates have risen by 15%. The initiative is expected to significantly reduce labour costs, improve equipment maintenance predictions, and boost product profit margins and overall revenue.

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