50+
Acre Facility
2,500+
Employees
350+
IP Cameras
98.7%
AI Detection Accuracy
Executive Summary: A leading industrial manufacturing plant with 2,500+ employees across a 50-acre facility engaged Unicircuit Engineering Services LLP to design and deploy a unified, intelligent security and safety platform. This case study presents our end-to-end approach — from assessment through go-live — integrating CCTV surveillance, biometric access control, real-time people counting, and AI-powered workplace hazard detection into one command-and-control ecosystem.
Client Challenges
Fragmented Legacy Systems
Disparate analog CCTV, manual logbooks, no digital access controls across 12 buildings.
Safety Compliance Gaps
Frequent near-miss incidents due to lack of real-time PPE and hazard monitoring.
Unauthorized Zone Access
No mechanism to restrict/track personnel in high-risk chemical and machinery zones.
No Real-Time Headcount
Emergency evacuation drills showed 15–20 min delays in personnel accounting.
Data Silos
Security, safety, and operations teams worked with non-integrated systems.
Regulatory Pressure
OSHA/local compliance mandates requiring automated safety monitoring.
Integrated Solution Architecture
350+ IP Cameras
4K resolution, IR night vision, wide-angle & PTZ coverage. NVR, H.265+ compression, 90-day retention. 12 radiometric thermal cameras for fire prevention.
Access Control System
Biometric + RFID multi-factor, zone-based clearance (8 security tiers), anti-tailgating mantrap corridors, visitor management, time & attendance, emergency override.
People Counting System
Stereo-vision 3D sensors at 45+ entry/exit points — 99.2% accuracy. Real-time occupancy dashboard, overcrowding alerts, instant emergency headcount (<60s muster).
AI Workplace Safety
PPE compliance monitoring (hard hats, vests, goggles), restricted zone intrusion alerts, spill/leak detection via thermal + visual, unsafe behavior detection. NVIDIA Jetson Edge + YOLOv8, 98.7% accuracy.
Implementation Timeline
Phase 1
Site Assessment & Design
4 Weeks
Phase 2
Infrastructure & Hardware
8 Weeks
Phase 3
AI Integration & Testing
4 Weeks
Phase 4
Training & Go-Live
2 Weeks
Measurable Results & ROI
Before → After Comparison
73%
Safety Incident ReductionFrom 48 to 13 incidents per month through AI-powered monitoring.
85%
Faster Emergency EvacuationMuster time cut from 18 minutes to 2.7 minutes.
40%
Drop in Unauthorized AccessZone intrusion events reduced via biometric control.
14M
Full ROI Payback PeriodComplete return on investment within 14 months.
Why Unicircuit Engineering?
End-to-End Expertise
Consultation, design, installation, commissioning, and maintenance — one partner for the complete lifecycle.
Vendor-Agnostic Integration
Best-in-class hardware/software, no vendor lock-in.
AI-First Approach
Proprietary AI models for industrial environments, 98.7%+ detection accuracy.
Proven Track Record
Manufacturing, oil & gas, logistics, government facilities.
24/7 Support & SLA
Dedicated NOC, 4-hour response SLA, preventive maintenance.
Scalable Architecture
Future-proof designs — add cameras, zones, AI modules without re-architecting.
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