Manufacturing plant security tips to help keep your facility safe

The importance of security for manufacturing plants

Industrial and manufacturing facilities face numerous types of significant security issues regularly, concerning internal and external threats. Integrated security solutions are essential in these environments to help ensure every aspect of plant operations is protected at all times, enabling facility managers to implement unique responses to the following risks.

Unauthorized access 

Access control is the first line of defense in manufacturing plant security, locking entry to the site, internal high-risk areas and access to potentially dangerous machinery behind traceable credentials. Manufacturing facilities can be attractive targets for organized and opportunistic criminals because large amounts of valuable goods, equipment and data are stored on-site.

Failing to address unauthorized access risks can expose facilities to multiple wider security and safety issues, including acts of violence and personal injury, as well as potential lawsuits related to breaches of industry regulations. An effective manufacturing plant security system will lock entry to all physical locations and digital solutions behind monitored access controls.

Health and safety hazards 

According to the Bureau of Labor Statistics, the manufacturing industry reported approximately 396,800 nonfatal workplace injuries and illnesses in 2023, while the construction industry saw around 169,600 such incidents in the same year. Additionally, the construction sector was also responsible for 19% of all fatal work injuries in 2021.

Security measures like access control solutions, security cameras and alarm systems are essential to prevent unqualified persons from using dangerous machinery and ensure hazardous materials are secured appropriately. When such tools are deployed within an integrated plant security system, teams can respond promptly to risks.

Acts of industrial espionage

Manufacturers often hold valuable trade secrets, making them prime targets for cyber espionage. Recent data indicates that the manufacturing sector is the most frequently attacked industry, accounting for 23% of global security incidents. Additionally, the average cost of a data breach in the industrial sector has risen to $5.56 million, reflecting an 18% increase from the previous year. These statistics underscore the critical need for robust cybersecurity measures to protect sensitive information and maintain operational integrity.

External and internal theft

Raw materials and saleable products stored in and outside manufacturing facilities can be attractive targets for organized criminals, with cargo theft alone accounting for almost $700 million in damages in 2023. Without permanently monitored plant security measures, facility operators may struggle to prevent and address attempted acts of external theft.

Manufacturing facilities can also be vulnerable to internal theft, whereby known employees attempt to steal goods and data for personal gain. Well-managed access control systems and physical protections are vital to help restrict access to valuable assets and information.

Criminal damage and vandalism

Manufacturing facilities can be vulnerable to criminal damage and vandalism by opportunistic intruders and criminals with intent. Vandals often find sites attractive as they’re usually far from populated areas, are inactive at night and have many available escape routes.

Plants may also be targeted by disgruntled ex-employees or individuals with a personal issue with the business, potentially leading them to commit intentional criminal damage. For operators to reliably identify and address such incidents, security measures like access control, weapons detection systems, alarms and remote-accessible IP surveillance cameras must be implemented.

Essential manufacturing plant security measures

To reliably protect sites from the above-mentioned threats, owners and managers must commit to developing and continuously improving bespoke manufacturing plant security systems. Business owners, facility managers and security staff must consider the following measures and technologies when designing and implementing security systems.

1. Risk assessments and security audits

To make the most efficient use of security budgets, and help ensure proposed measures will be positioned to address realistic threats, thorough risk assessments should be performed. Internal and external security professionals should walk through the facility to highlight and document all potential vulnerabilities, and this information should be used to inform security decisions.

Teams should also review previously reported security and safety incidents to better understand present threats. Bespoke manufacturing plant security measures can then be implemented to address these issues, with provisions made to audit newly implemented systems regularly to account for novel safety threats and vulnerabilities uncovered over time.

2. Video security and observation

Manufacturing security cameras are one of the most important and versatile components of effective plant security systems, with bullet, dome and PTZ cameras utilized to secure clear footage of high-risk areas. Positioning cameras to cover perimeters, entrances, internal storage facilities and valuable equipment enables security staff to identify threats at all times.

High-resolution cameras should be prioritized to help security teams identify key details in captured footage. Facility managers may also choose to implement cloud-based security management systems so camera feeds can be accessed remotely and utilize video analytics tools capable of identifying and warning staff of suspicious activities autonomously.

3. Access control systems and perimeter security

Unauthorized persons can be deterred from accessing manufacturing plants through perimeter security measures. Physical barriers like fences, gates and bollards act as a first line of defense, preventing unknown persons from entering secure areas via unguarded access points and making it difficult for them to observe work activities from outside.

Entry to the site can be further restricted using access control systems, with employees and authorized guests needing to present issued credentials to gain access. Manufacturing plant security systems may use multiple types of credentials to secure high and low-risk areas, such as key fobs for communal areas and biometric scans for equipment and asset access.

4. Security guards and physical security measures

Business owners must employ responsible security professionals to ensure technological plant physical security measures are well-operated and properly maintained. Guards stationed at entry points can manage access systems and act as a physical presence to deter intruders, with access to cameras and alarms offered through remote-access cloud management systems.

Under a cloud management platform, security personnel on patrol can access live security feeds and receive real-time alerts about triggered security devices, enabling teams to enact fast and informed incident responses. Such a system allows on-site teams to cover all high-risk areas like cargo bays, entry points and storage areas appropriately.

5. Employee training and security policies 

Manufacturing plant security measures and technologies can only be truly effective if all stakeholders understand how to safely navigate them. Employees must be trained to use active security devices and report suspicious activities, with all staff made aware of where security systems are located to improve the likelihood of incidents being identified.

Plant security policies must also be implemented, covering how staff and authorized guests are expected to navigate active facilities. For example, tiered access may be granted to staff based on their employment status, with policies and protocols in place to make sure visitors sign into the site on entry and are accompanied by an authorized staff member at all times. 

6. Lockout tagout (LOTO) safety systems 

LOTO systems are an essential manufacturing plant security measure in facilities where heavy machinery is commonly used. To prevent worker injuries during maintenance and repairs, LOTO procedures must be implemented, using policies and technologies to ensure machines are completely shut down.

An effective LOTO procedure will include isolating equipment from all power sources, a physical locking device to prevent the accidental manipulation of machinery and a tag that can be affixed to the machine and used to warn other staff that maintenance work is being performed. LOTO procedures should be regularly reviewed to account for new technologies.

7. Integrated security systems 

To help enhance the efficacy of manufacturing plant security measures and improve incident response times, security teams should consider developing integrated commercial security systems. Via integration, siloed security devices like access readers, cameras, alarms and manufacturing IAQ sensors can be linked, with stimuli detected by one solution used to instantly inform the operation of another.

For example, if unusual motion is detected by sensors outside, nearby security cameras may automatically record and flag relevant footage, with access locks and alarms programmed to engage instantly. Integrated systems can also be deployed to protect machinery, with access to equipment instantly blocked in response to anomalous requests or failed access attempts.

Enhancing security in manufacturing plants with video solutions

In fast-paced manufacturing environments, video security plays a critical role in protecting assets, preventing theft and boosting operational efficiency. Video security products like Pelco cameras are specifically designed to meet the unique needs of manufacturing plant security, offering advanced technologies that keep your facility safe and secure. 

Preventing theft and protecting assets

Pelco’s video security devices help deter theft and unauthorized access by providing continuous, high-definition video of critical areas. With Pelco’s advanced cameras and AI-powered analytics, security teams can quickly identify suspicious activity and take immediate action, ensuring your manufacturing plant security procedures are always effective in preventing losses.

Real-time viewing for smarter decision-making

Real-time video feeds allow security teams to observe plant operations around the clock to enforce plant security measures. Pelco’s customizable systems offer live video viewing from any location, making it easier for plant managers to oversee operations and security from a distance. This capability streamlines decision-making and allows for faster responses to any security threats.

Specialized cameras for manufacturing sites

Pelco offers a variety of camera types, each suited for different environments within a manufacturing plant. Pan-tilt-zoom (PTZ) cameras offer high flexibility and provide detailed coverage of large areas with adjustable views. For areas requiring ²⁴⁄₇ security in low light, Pelco’s infrared and thermal cameras provide clear imaging, even in the darkest conditions. These specialized cameras are ideal for warehouses, production floors and storage areas, where high-value assets need constant security.

Flexible, customizable systems

Manufacturing plants require security systems that can adapt to their unique environments. Pelco offers flexible solutions designed to withstand harsh conditions and integrate with existing infrastructure. With compatibility across access control and alarm systems, Pelco’s technology supports a comprehensive approach to manufacturing plant security.

How to choose the right manufacturing plant security partner

When developing and implementing manufacturing security systems, facility managers and security teams should consult external security integrators to help ensure newly proposed solutions can adapt to unique requirements. These professionals can provide expert guidance regarding devices and configurations best suited to specific work environments.

Consider the following best practices when searching for an organization to fulfill this role.

1. Prioritize experienced security professionals

An effective security systems integration team will be able to cover any skills gaps present in existing security teams. Successful partners will have experience working with organizations in the manufacturing industry, with in-depth knowledge of the risks associated with normal operations and those that poorly implemented security solutions could expose.

When discussing potential partnerships, request information about previous projects and ask which qualifications the organization’s integrators hold. Trusted professionals will hold a Certified Security Systems Integrator (CSSI) qualification, and have experience working on access control, video security, alarm and sensor installations in manufacturing environments.

2. Focus on relevant and future-proof technologies

Alongside ensuring hired personnel are appropriately knowledgeable, it’s also important to ensure proposed technologies can provide long-term protection. Focus on organizations that develop or are licensed to work with modern security technologies, receive regular updates and are certified to provide comprehensive security under extended warranties.

An effective manufacturing plant security system will be scalable and adjustable, with tools designed to adapt to changing needs. Consider how easy it may be to add new devices to proposed systems, or whether adding an entirely new site’s infrastructure to the same security management platform may be possible to help streamline future organizational expansions.

3. Consider upfront and ongoing costs 

A budget will need to be devised prior to approaching potential integration teams, with facility owners, managers and security teams working together to ensure appropriate, cost-effective manufacturing plant security solutions can be developed. Teams will need to consider costs associated with purchasing relevant technologies and installing them throughout the facility. 

Some security systems developers may offer discounts depending on the number of devices purchased or as part of an agreement that their personnel perform the installation. It’s also important to consider ongoing costs associated with future hardware and software updates.

4. Ask about continuous support and maintenance

Even the best-implemented manufacturing plant security systems will need to be maintained over time, with repairs and updates needing to be implemented by qualified professionals. Before choosing a security partner, owners and managers must discuss how maintenance procedures will be handled, including whether fees will be separate or included in a package.

Managers should also consider that plant security systems may be misused or accidentally damaged, requiring support from the service provider to get things back up and running. An ideal security partner will have a ²⁴⁄₇ customer support line in place to cover such instances.

Conclusion

Designing, implementing and maintaining bespoke security systems is vital in manufacturing environments, with owners and operators needing to ensure the safety of employees and the security of valuable assets. Appropriate plant security systems will offer continuous coverage over key areas, help to restrict entry to high-risk locations and support automated responses.

Alongside selecting appropriate technologies, stakeholders will need to ensure solutions are installed correctly and developed as part of an integrated system. Facility owners, operators and security teams should work with experienced manufacturing plant security partners to create bespoke, future-proof solutions, as well as ensure the delivery of continuous support.