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The Top Manufacturing Security Solutions Companies Can Implement to Protect Their People

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The Top Manufacturing Security Solutions Companies Can Implement to Protect Their People

Despite the difficulties 2020 posed, manufacturers have worked hard to help global operations continue running efficiently. To keep up with demand, however, companies are still operating facilities where hundreds or thousands of employees are on the floor at once. Within these large, densely populated facilities, following health guidelines like social distancing becomes a frustrating exercise. While managers certainly want to protect their people, they face unique challenges in today’s environment.

Manufacturers are prioritizing holistic employee safety, and manufacturing security solutions are now available to help facility managers realize their goals of promoting workers’ health and safety. Here are three specific technologies companies are using to better protect their people.

Physical identity and access management (PIAM) solutions

Many facilities have limited the number of ingress and egress points in an effort to better manage people flow. Even with automated screening solutions, however, high-volume employee throughput events like shift changes place severe strains on processing employees. Chokepoints emerge where people congregate in long lines, increasing the risk of transmitting germs.

Increasing throughput capacity and reducing risks to employees and visitors are top priorities that automated, touchless PIAM solutions are suited to meet. For example, employees and visitors can take at-home health screening questionnaires on their mobile devices. Based on the self-assessment, healthy visitors can receive a QR code to scan for facility entry at an access control point.

Should an employee self-report feeling unwell, a system with integrated analytics can facilitate cross-department communication to resolve potential issues. For instance, the system can automatically notify a human resources department, which can take further action like providing employees with self-quarantining guidelines while helping other departments adjust as needed.

Within the facility, other systems can protect workers on the floor by regulating people inflows and outflows. People counting systems, updated in real-time as workers enter and exit the facility, provide accurate employee counts to ensure areas don’t become too congested. Video surveillance system integrations can also assist managers, should they want to to rearrange floor layouts to promote more social distancing.

Human temperature screening

Concerns about illness have raised the profile of human temperature screening (HTS) as part of a security system. HTS systems use thermographic cameras to read a subject’s skin temperature from a distance, automating significant portions of a facility’s health screening process. Integrated systems allow for elevated temperature detections to trigger notifications for further screening or automatically deny facility access. While elevated temperature alone isn’t enough to determine if an employee is sick, HTS provides another layer of support within a comprehensive worker protection plan.

Manual screening involves placing staff equipped with thermometers at every entry point — an inefficient process that an HTS system can help to automate. Each system does have its own set of use parameters to follow, including best practices on sensor placement, scanning area and subjects’ interactions with devices. Some also need additional calibration equipment, such as a blackbody — a reference point that’s heated to a specific, stable temperature within the scanning area.

Installing and integrating an HTS system has significant benefits for holistic employee safety, but facility managers have other decisions to consider as well. For example, companies need strict policies on who can access the sensitive health information these systems gather and where it’s stored. Any system must be compliant with regulatory requirements from entities like GDPR, BIPA and others. Protecting employees’ physical health is important, but so is protecting their private information.

Integrated video surveillance systems

Standalone security solutions can contribute significantly to ensuring workplace safety, but facility managers can realize more benefits through integrations with existing systems. Video surveillance systems in particular have much more to offer. Using data and analytics drawn from multiple sources, they can provide protection beyond merely theft deterrence.

For example, facility managers can leverage “heatmaps” by merging internal video surveillance data with a floor plan. Using this information, they can identify and address the “hot spots” where employees congregate or come into close contact, such as crowded break rooms. With consistent monitoring, managers can better understand whether changes like adjustments to workstations on the floor are effectively promoting more social distancing.

Video systems also help facilities save on other potential costs like workplace incident verification. Interior video surveillance can track employee behaviors like social distancing and proper use of PPE. If an employee files a compensation claim, managers can generate an auditable trail of evidence to use in proceedings. Facility managers can also use system data proactively to improve training sessions and identify opportunities to encourage behavioral changes in employees.

Manufacturing facilities keep the world moving — and shutting down is often not an option. Still, managers can use security solutions to better protect their people while their facilities remain open. With automated PIAM and screening solutions, along with existing systems integration, manufacturers can apply data-driven approaches in their efforts to ensure workplace health and safety, all while managing their operations more efficiently.

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Lance Holloway is a Senior Solutions Architect at STANLEY Security. Lance has served in the physical security industry for over 27 years. Today, he is part of STANLEY Security’s Enterprise Solutions Architect team, which focuses on research, design and workshop forums to aid customers in achieving even the most complex security goals in today’s evolving technology landscape.

manufacturing

How to Gain an Advantage in Manufacturing Facilities During Post-Crisis Times

In the United States today, as many manufacturers have entered post-crisis phases in their facilities, some have a much different business model than they did entering 2020. Others, such as those who manufacture medical supplies, craft supplies, and pet supplies, don’t look much different than they did at the beginning of the year, outside of a backlog of orders that they are doing their best to fill in a timely fashion. 

Some manufacturers were surprised at how well their products did during crisis times earlier in the year. For example, LumenAID, a manufacturer of portable, solar-powered lanterns that double as a phone charger, has seen a huge uptick in sales. It seems with people preparing for times unknown, emergency supply manufacturers of this type can’t fill the shelves quickly enough. Other manufacturers were well aware of the need for their products, like office chairs, school supplies, and pet training products. The comforts of home for those stuck at home became the quick front-runners in sales, and suppliers with stored inventories were pleasantly surprised with their sales numbers. 

Yet, for some manufacturing facilities, especially in the hardest-hit areas of the country, it wasn’t a lack of demand that shut down the product lines. It was the lack of production associates able to make it to the facility. Quarantine, public transportation being shut down, mandatory stay at home orders, and a lack of child care left some facilities looking much like a part of a ghost town. The most prepared of those production facilities put that time in the hands of their plant engineers and maintenance managers, and for good reason. 

In an industry where it is often common for machines to run in 72-hour cycles or longer to meet production needs, the downtime came as a blessing in disguise to many engineers and mechanics. They strapped on their tool belts and began performing preventative maintenance that had been put off, in some cases, until the machinery refused to operate any longer. While many production associates were home by no choice of their own, skeleton crews of mechanics and engineers quietly worked behind the scenes to ensure that the production lines that these associates returned to were repaired, lubed, and ready to run for another 100,000 rotations. 

While You Were Out…

Although we’re not positive what the “new” normal will look like, manufacturers are doing their best to get back to business as usual.  One key element is ensuring that their facility can handle the workload, and well-maintained production lines are a fundamental part of that process. Even those production facilities that did not have to implement the Emergency Contingency Plan and were still able to run socially distanced production shifts were finding difficulty in getting the parts necessary to perform preventative maintenance on their production machinery. 

Facilities with CMMS systems that handled their maintenance parts rooms were seeing just how much those systems did for them, possibly for the first time ever. These manufacturing facilities were able to perform preventative maintenance as normal, because of the reorder point set in the CMMS, ensuring that the parts to perform the maintenance were, indeed, stocked in the parts room. Due to the human element being removed by CMMS, the moment the last technician performed the PM and took the part off of the shelf, the system already issued a purchase order and had a replacement on the way. 

Full Speed Ahead

As manufacturers are getting back into the swing of things, especially those fortunate enough to have orders that they need to fill, the appreciation for well-maintained machines is at an all-time high. With most of the country able to return to work, and production lines full of associates thankful to be back on the line, returning to a facility with newly maintained machinery is just another day in manufacturing. However, from the mechanics and engineers who worked solo overnight shifts to prepare for firing the production lines back up, there is a nearly audible sigh of relief when the conveyor belts start running. 

Preventative maintenance was, in some facilities, the only items that could be completed during the height of the crisis, and production managers are reaping the benefits of those overhauls at the moment. In notoriously under-maintained facilities, the quietly operating, well-oiled machinery that is producing post-pandemic inventory is a sign of moving into stronger financial times. 

As A Post-Crisis Model

If your production facility is running at a pre-pandemic rate, you’ve more than likely gotten back into the normal preventative maintenance schedule, less a few adjustments. For those facilities that don’t have the need to run full production shifts at this point, investing labor dollars into machine maintenance is a smart move. Although the need may not be there at the moment, when the orders do come in, the ability to perform full production runs without stopping because of unperformed routine maintenance will be one more way to stay competitive. 

Well maintained machinery produces to specification, which reduces scrap and reworks exponentially. By producing a consistent and reliable product, your facility develops a reputation for quality, and that is priceless in post-crisis America. By ensuring that your production facility is adhering to a preventative maintenance schedule, you’re committing to running products that are manufactured to strict standards at a time when they’re more valued than ever. A CMMS is another tool in a manufacturer’s facility to ensure that they’re producing items that meet or exceed the expectations of their customers. 

In addition, maintenance costs are decreased by 5-10 percent by having a preventative maintenance program in place in a manufacturing facility. It also decreases the time spent repairing machinery by 20-50 percent. In terms of looking out for the bottom line as manufacturing facilities try to push forward in uncertain economic times, a strong preventative maintenance program makes sense. In saving both time and money long term for manufacturing facilities, preventative maintenance can help manufacturers get a leg up in the post-crisis American economy. 

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Co-Founder and CEO of Redlist. Raised in a construction environment, Talmage has been involved in heavy equipment since he was a toddler. He has degrees and extensive experience in civil, mechanical and industrial engineering. Talmage worked for several years as a field engineer with ExxonMobil servicing many of the largest industrial production facilities in the Country.