A Spotlight on Security for Manufacturing Companies

As successive news stories will confirm, security breaches can bring manufacturing companies to their knees. Although cyberattacks dominate the headlines, security threats aren’t limited to the digital realm. They come from multiple angles.

Security measures must cover every aspect of a complex supply chain — from raw materials to the finished product — without compromising operational efficiency. What’s more, manufacturing security isn’t just about protecting profits. It’s also about employee safety in an environment which, by its very nature, presents a physical risk.

To help you manage the risks, we’re shining a spotlight on security for manufacturing companies.

Start with a risk assessment

While almost every manufacturing firm has a supply chain, the risks and logistics vary significantly from one business to another. A risk assessment determines where you’re vulnerable, both physically and digitally. It helps you focus on which security measures are necessary to protect the supply chain, when and where to implement them.

Your risk assessment can be broken down into 3 stages — identifying assets, identifying threats and assessing the impact of the identified threats.

1. Identify assets

• Physical Assets: Identify all tangible assets such as machinery, equipment, buildings, raw materials and finished products.
• Information Assets: List all intellectual property, customer information and operational data, both digital and physical.
• Operational Processes: Document manufacturing processes and production lines which are crucial for business continuity.

2. Identify the threats

• Identify threats: It could be cyberattacks, insider threats, physical theft, vandalism or supply chain attacks.
• Assess vulnerabilities: Look for weaknesses in physical, procedural and IT security. Watch out for weak access controls or network security, outdated alarm and CCTV systems or inadequate employee training.

3. Assess the impact

• Estimate the impact: For each threat, estimate how likely it is to occur and the potential consequences — financial loss, downtime, reputational damage and so on.
• Prioritise the risks: Rank the risks according to their likelihood and potential impact, then prioritise the most critical.

Some threats and vulnerabilities will be easy to identify. Others won’t be obvious, so it’s wise to consider a professional risk assessment. If you would like us to do this for you, please get in touch with the Classic Services Group team. We’d be happy to help.

Perimeter security

Robust perimeter security is crucial. It’s your first line of defence. High walls and fences are a good start, but they’re not enough to stop someone who’s determined to break in.

Perimeter security for manufacturing involves layered defences. For example, consider integrating physical barriers with electronic systems such as PIDS (perimeter intrusion detection system). It detects unauthorised attempts to cross a defined boundary and provides an early warning to security teams, allowing a swift response before the incident escalates.

CCTV towers are another good option. At 6 metres high, they’re particularly effective for watching over large areas such as container yards or car parks. Also, because they use solar power and cellular connectivity rather than a wired connection, CCTV towers are highly mobile. You can reposition them quickly and easily.

Access control

Access control presents many challenges which are unique to manufacturing sites. With hundreds of employees working different shift patterns, it’s important to strike the right balance between security and efficiency.

Large numbers of authorised people and vehicles need smooth, uninterrupted access — yet site access by potential criminals or a disgruntled ex-employee could be dangerous and costly.

This problem can be solved with the right combination of access control systems. You could, for example, combine speed gates or turnstiles with smartphone-enabled readers, biometric or card readers. This allows effortless access for multiple staff, but prevents piggy-backing by intruders.

Combining access control with AI-powered CCTV systems could help you manage vehicle access, and reduce queuing at the same time. There are also cloud-based and AI-powered platforms which offer a wealth of features — real-time monitoring, role-based access control, remote management and more.

Smart CCTV surveillance

Modern CCTV systems come equipped with AI-enabled video analytics. This powerful technology not only strengthens physical security, it also helps protect the safety of employees.

Smart cameras learn to recognise normal patterns of behaviour in a workplace. They automatically analyse video feeds in real-time to detect anomalies, such as a worker falling to the ground, and issue an immediate alert.

Smart CCTV can recognise faces and objects, identify vehicle number plates, trigger swift alerts for suspicious behaviour or unauthorised access, and even let you know if a worker is not wearing the required safety clothing.

Remote CCTV monitoring

Remote CCTV monitoring gives you continuous coverage by responders at an alarm receiving centre who deal with threats in real time.

When an alarm or sensor is triggered, responders analyse the footage and filter it for false activation. If it’s a genuine threat, remote responders detect it fast and act before the incident escalates into theft of stock, vandalism, equipment damage and operational disruption.

Moreover, the combination of live footage, AI-driven analytics and human operators considerably reduces false alarms. The system can differentiate between legitimate threats and normal manufacturing activities, preventing unnecessary calls to keyholders or the emergency services.

Security officers

SIA-licensed security officers provide a powerful, visible deterrent to intruders and robust protection for high-value assets.

On a manufacturing site, they protect both staff and property. Besides controlling access, officers are trained in dispute resolution, as first responders to medical emergencies, and as fire marshals. They will respond with swift professionalism to security breaches and can, if required, help enforce safety protocols such as PPE use.

For an even greater level of protection, consider K9 security, where a highly-trained handler and security dog work together as a team. It’s an ideal option for large manufacturing sites. A dog’s keen sense of smell and hearing, combined with its speed and agility over wide areas, is a powerful crime-prevention measure.

Inventory security

Thieves don’t always steal entire shipments or large quantities of manufacturing materials. Instead, they often skim off small amounts to make the theft less obvious.

Tamper-evident security seals and advanced digital locks provide both a clear, visual indicator of the problem and a strong prevention measure.

In addition, consider an inventory management system which provides real-time tracking and monitoring throughout the supply chain. These systems can detect even the smallest discrepancy in inventory levels, helping you to spot thefts early.

Staff training

Staff training is essential. While most employees don’t set out to cause intentional harm, the fact is that employee ignorance is a significant threat to manufacturing security.

Training should occur regularly, and information must be frequently updated to keep pace with evolving security threats. Training sessions should include:

• Site security systems and procedures
• Identifying suspicious behaviour and potential safety issues, and where to report them
• Cyber security and cyber safety
• Secure communication practices
• Safe transportation of goods
• Response procedures for specific incidents
• Security maintenance procedures

Conclusion

There is no one security solution for every manufacturing business. Each will have their own unique supply chains and operational procedures, as well as differing site security requirements.

For a no-obligation discussion about your own requirements and a tailored solution, please get in touch with Classic Services Group. We’d be happy to help.