From firefighting to forecasting: Edge AI and private 5G redefine industrial resilience

Machines don’t have to fail silently anymore. Today, turbines can send alerts about imbalances, valves can warn of fatigue, and robotic arms can detect microdefects as they happen. This is the new reality made possible by the combination of edge AI and private 5G.

For years, maintenance has been mostly reactive. Organizations fixed problems after they happened, just as you’d call the fire department when there’s a fire. Now, edge AI and private 5G turn every asset into a smoke detector — spotting heat, pressure or vibration anomalies before the flames even start.

This is a fundamental shift from firefighting to forecasting — and it’s changing how industries operate.

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How edge AI and private 5G power predictive maintenance

At the heart of this transformation is a simple but powerful idea: Process data where it’s generated, and transmit it instantly and securely. Here’s how it works:

• Real-time intelligence at the edge: Edge computing processes sensor data locally, on machines or nearby gateways. Because it’s not sent to the cloud for processing, anomalies such as overheating or vibration spikes can be detected instantly. And intelligent, edge AI-generated responses like shutdowns, alerts and adjustments are just as fast. It’s like giving machines a sixth sense — one that doesn’t rely on distant servers or delayed decisions.
• Ultrareliable, low-latency connectivity: Private 5G networks offer secure, high-speed connections across factory floors, mines and energy grids. They support massive IoT deployments with minimal delay, so AI models receive the continuous streams of high-quality data they need to work their magic.
• Better coverage in harsh environments: Private 5G reaches where Wi-Fi can’t. This means you can place sensors in hard-to-reach spots — underground, offshore or across sprawling facilities — without compromising performance. Even remote assets are monitored and maintained intelligently, closing the gap between visibility and action.
• Autonomous decision-making: Shop-floor operators once relied on intuition and experience. Now, AI models trained on failure patterns can predict when equipment is likely to fail, and machines instantly communicate their needs. Maintenance crews can be dispatched proactively, reducing downtime and avoiding catastrophic failures.
• Secure by design: Private 5G offers built-in encryption, physical network separation and compatibility with zero trust security Combined with on-premises edge computing, it creates a powerful shield — keeping sensitive data onsite and critical infrastructure secure.

Where can industrial private 5G and edge AI be implemented?

This isn’t theory. It’s already happening — in production, logistics, energy delivery and other sectors.

A remote energy-generating facility that once relied on satellite uplinks and manual inspections now runs on a private 5G backbone. Hundreds of sensors stream real-time data to edge nodes. When a turbine shows early signs of imbalance, the system triggers safety protocols and dispatches a crew with the right parts, before a failure occurs.

On a manufacturing line producing high-precision components, robotic arms can now detect microdefects and make adjustments in real time. By solving the problem of unpredictable tool wear, scrap rates have dropped and component quality has improved.

In logistics, mobile fleet operators traversing rugged terrain transmit diagnostics over 5G networks. Edge AI can predict engine degradation and battery health, which means vehicles are serviced proactively — reducing truck rolls and saving millions annually.

And a smart grid operator can now deploy edge computing at their substations, enabling AI models to detect transformers that are overheating within milliseconds, while edge nodes reroute power autonomously to prevent outages and protect infrastructure.

These wins are part of a broader shift toward intelligent infrastructure, with assets that can observe, learn and adapt.

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In practice: The numbers speak for themselves

Private 5G and edge AI are now proven investments that solve real-world industrial problems and enable use cases that would not otherwise have been possible:

• 70% of industrial organizations using edge and private 5G are running AI-driven predictive maintenance.
• 87% saw an ROI within 12 months, through reduced downtime, improved safety and smarter resource allocation.
• 86% reported reduced ongoing costs.

3 steps to edge AI and private 5G success

To unlock the full potential of edge AI and private 5G in your organization, adopt a strategic, streamlined approach to deployment and integration. At NTT DATA, we recommend the following:

1. Simplify deployment with network as a service (NaaS): NaaS bundles design, installation, operations and ongoing support — including integration of private 5G, edge AI and IoT components — into a single, streamlined service. It reduces complexity, shortens implementation timelines, lowers up-front costs and minimizes the need for deep in-house technical expertise.
2. Cultivate a holistic ecosystem: Partnering with experienced integrators and diverse technology providers (spanning radios, edge nodes, core networking and AI platforms) for seamless end-to-end integration and the ability to scale as needed.
3. Implement a phased rollout strategy: A tiered implementation model, anchored by clearly defined use cases, allows you to gain practical experience, demonstrate early value and refine your approach before expanding across the organization.

Our real-world impact with quantifiable results

NTT DATA has deep experience in the convergence of edge AI and private 5G, with a comprehensive portfolio of services and solutions designed to make industrial operations more efficient and facilitate predictive maintenance.

We were named a Visionary in the 2025 Gartner® Magic Quadrant™ for 4G and 5G Private Mobile Network Services.*

In Brownsville, Texas, we’re transforming the cityscape with smart solutions powered by private 5G, creating a digital nervous system that spans every street, sensor and service. With blanket coverage for high-bandwidth IoT assets, Brownsville is unlocking real-time intelligence — from AI-enhanced cameras that help officials fight crime to airport systems that boost the efficiency of security teams by up to 95% by automatically detecting anomalies.

It’s not just a smarter way of running a city — it’s leaner, too. By replacing fiber trenching with wireless backhaul, the city is set to save up to $100,000 in civil construction costs, plus thousands more annually by eliminating public SIM charges.

And in Kentucky, we’re helping Schneider Electric deploy private 5G at their Lexington Smart Factory to supercharge IoT connectivity and edge analytics. The result? Machine-vision systems that spot faults and wear in real time, which facilitates predictive maintenance and elevates both energy efficiency and product quality.

How can we make a difference in your organization?

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* Gartner, Magic Quadrant for 4G and 5G Private Mobile Network Services, Sylvain Fabre, Peter Liu, et al., 6 January 2025

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