Wada Manufacturing Factory

Location: Wada Industrial Area, Maharashtra
Industry: Heavy Machinery & Component Manufacturing
Facility Size: ~45,000 sq. ft. (Manufacturing, storage, admin block)
Employees: Over 110 staff working in rotating shifts
Project Duration: 3 weeks (from audit to commissioning)

Project Background

Faced growing concerns around security vulnerabilities, especially:

  • After-hours unauthorized access to open yards and tool storage
  • Lack of visibility across blind spots in warehouses
  • No real-time monitoring of staff entry/exit during multiple shift transitions
  • Fire safety risks due to stored lubricants and multiple sub-panels
  • The existing system had basic analog CCTV, prone to downtime and poor image clarity

challenges Identified

Through a security audit, James Electricals identified the following risk areas:

  • Perimeter breach potential at night with inadequate lighting and surveillance.
  • Zero access restrictions to sensitive areas like electrical control rooms and the fabrication unit.
  • Poor quality CCTV footage made it difficult to identify individuals.
  • Lack of a fire detection system in chemical storage and transformer rooms.
  • No integration between various systems — manual response dependency in emergencies.

Our Integrated Solution

We developed and executed a tailored Industrial Security Plan, using industry-grade equipment and standards:

  1. Advanced Perimeter Surveillance
  • Installed 12 long-range bullet IR cameras with 40m night vision along the outer boundary.
  • Motion detection sensors to trigger floodlights and alert guards between 7 PM – 6 AM.
  • Integrated mobile alerts for real-time viewing and response by plant security heads.
  1. Access Control & Staff Segregation
  • Biometric fingerprint scanners are at the main gates and staff entrances.
  • RFID-tag-based access in high-risk zones (transformer yard, substation, raw material room).
  • All entry logs are auto-synced with the central attendance system.
  1. Warehouse Surveillance
  • 180° dome cameras installed in:
  • Loading bays
  • Inventory aisles
  • Packaging sections
  • Connected to DVR system with 30-day storage and HDMI screen in the admin cabin.
  1. Fire & Emergency Safety System
  • Installed EN-54 compliant smoke and heat detectors in electrical panel areas, maintenance bay, and storehouse.
  • Sounder-strobe fire alarms for quick evacuation.
  • Emergency lights and exit signage with 3-hour backup power.
  • Fire control panel with zonal monitoring in the plant manager’s cabin.
  1. Command & Monitoring Setup
  • Established a central control room with multi-channel DVR monitor, network connectivity, and backup storage.
  • The plant manager and owner have remote access via a mobile app for live and recorded footage.
  • Configured alarm integration, so fire detection or unauthorized entry triggers immediate SMS/email alerts.

Project Highlights:

  • 22 HD surveillance cameras installed
  • 6 biometric + RFID access points
  • Fire alarm system with 6 zones
  • 1 central monitoring room setup
  • 3x improvement in overall security coverage