Sector
Manufacturing
A plant is not one building. Sheds, yards, gates, stores, a weighbridge, and half a kilometre between them. One security cabin is expected to watch all of it. We design and maintain security across manufacturing and process facilities in Mumbai and across India, specified for the distances involved and for the fact that nobody can watch a hundred cameras at once.
On a plant, a security system that stops a line costs more per hour than the system did. Every design decision here is made against production continuity first, and the most common mistake is specifying an office system for an industrial environment.
What actually goes wrong
The site is too big to watch, so nobody watches it.
| What fails | Why it fails | What it costs |
|---|---|---|
| A hundred cameras and one screen | Coverage was specified by area, and nobody specified who would look at it. | An operator watching a hundred views is watching none of them. The footage exists and nothing is ever noticed live. |
| The material gate and the weighbridge do not reconcile | Two records, two systems, joined by a register and a person. | You know a vehicle came in and what it weighed. You cannot prove they were the same event, and that is exactly where losses sit. |
| Perimeter detection switched off in month three | False alarms from wind, animals and vegetation, never re-tuned after the plant went live. | Half a kilometre of boundary with nothing watching it, and the drawings still show it as protected. |
| Cameras die in the environment they were put in | Dust, heat, vibration, wash-down, chemical vapour. Housings specified from a catalogue rather than for the shed they hang in. | Coverage degrades shed by shed over two or three years and nobody reports it, because nothing announces it. |
| Contractor access is a register at the gate | Shutdowns bring hundreds of temporary people and no system was designed for them. | The population with the least accountability leaves the least trace, in the weeks when the plant is most exposed. |
| Scrap and dispatch covered from the wrong angle | Cameras aimed at the yard, not at the loading point. | Excellent footage of a vehicle. Nothing of what was put into it. |
Nobody can watch a hundred screens
Your plant is covered. That is not the same as your plant being watched.
Most plants we assess have enough cameras. What they do not have is anybody able to look at them. One operator, one shift, a wall of views, half a kilometre of boundary, and a gate that is busy. Everything is recorded and nothing is noticed.
So the system becomes an after-the-fact tool. A loss is discovered at stock-take, or a claim arrives, and somebody spends two days scrubbing footage to find ninety seconds.
This is the one problem on a plant that technology has genuinely solved.
Analytics can watch what a person cannot: a vehicle stopped where no vehicle should stop, a person in a zone during a shift when nobody should be there, a gate opened outside its window, a load moving at an hour with no despatch scheduled.
It is not a new system. It runs on the cameras you already have. What it changes is that the plant tells you at the time, rather than telling you three weeks later when you go looking.
Find out what your cameras could be telling youWhat we carry here
- Surveillance and analytics
- Gates, weighbridge, yards, sheds, stores, scrap and despatch
- Rules set against your own operation: zones, hours, vehicle movements, loading points
- Alerts to a person who can act, not a report nobody opens
- Access control
- Sheds, stores, control rooms and restricted process areas as separate zones
- Shift-aware, so who may be where depends on when
- Contractor and shutdown access issued with an expiry, in numbers
- Intrusion & perimeter
- Detection along the boundary, zoned so an alarm names a location
- Tuned after the plant is live, not at commissioning, so it stays switched on
- Verified by camera rather than acted on blind
- Fire & life safety
- Detection appropriate to the process, the dust and the materials present
- Interlocks that reach the plant systems that have to respond
- Tested and recorded rather than certified once
Building management and AV are specified where the facility requires them.
The same six stages
Distance is the difference. Everything here is further apart than it looks on a drawing.
- 01 Outside the gate Approach roads, standoff and plate capture, often several hundred metres from anything else.
- 02 Entry The material gate, the staff gate and the weighbridge. Three decisions that must reconcile and usually do not.
- 03 Inside the building Movement between sheds, across yards, in the open. Coverage continuity is the hardest thing on this site.
- 04 Who goes where Zoning follows the process and the shift, not the floor plan. Who may be near which machine at which hour is a safety question as much as a security one.
- 05 Work areas Sheds, stores, plant rooms and a fire strategy for the materials actually present.
- 06 Control room The security cabin. Whether it can see anything useful, and whether anything reaches it in time to matter.
Proof
We do not publish our clients' names in this sector, and we will not publish yours.
Year seven
Coverage on a plant does not fail. It gets outgrown.
A shed goes up. A yard is repurposed. A new line changes where material moves. A boundary is extended. Nobody tells the security system, and nobody re-walks it.
Every camera is working. Every one of them is pointed at the plant as it was three years ago. The coverage on the drawing has not changed and the plant underneath it has, and the only way to find that out is to walk it with the layout in your hand.
Also on this
Find out what your cameras could be telling you.
We walk the site against the camera layout, test every device, and show you which of the cameras you already have could be watching for the things you currently find out about three weeks later.
The assessment is chargeable, quoted against the site, and adjusted in full against the first year if you take cover. Where cover is not taken, the fee covers our team’s time on site and the report we leave behind, and the report is yours either way.
Chargeable, and adjusted in full if you take cover.
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