Implementing Access Control Systems in Manufacturing: Best Practices

Physical security for manufacturers, Manufacturing facility protection, Perimeter security solutions, Access control systems, High-risk asset protection, Visitor management systems, Vehicle movement controls, Goods-in and goods-out monitoring, Physical security, Physical information security, CCTV, Perimeter, Guarding, Access control, Intruder alarm

Access control systems are critical to manufacturing security, ensuring only authorised individuals can enter specific areas or use certain resources. They help protect valuable assets, maintain safety in hazardous zones, safeguard intellectual property, and ensure compliance with regulations.

This blog provides an in-depth look at access control in manufacturing facilities, covering key types of systems, their benefits and challenges, and actionable best practices for implementation. It also examines the role of security personnel, integration with other security measures, technological advancements, compliance considerations, cost factors, training needs, and future trends.

Importance of Access Control Systems in Manufacturing

Access Control Systems (ACS) are electronic security systems that regulate entry into protected areas in a facility through authentication and authorisation methods. In manufacturing, ACS determine who can enter or exit certain zones on the factory floor, warehouses, or offices, thereby preventing unauthorised access and incidents.

Key reasons these systems are important in manufacturing include:

Asset Protection: Manufacturing plants house expensive machinery, raw materials, and products. Access control ensures only authorised staff can reach these assets, reducing theft or damage.
Workplace Safety: By limiting entry to dangerous or sensitive areas (e.g., equipment rooms, chemical storage), ACS reduce the risk of accidents and ensure safety protocols are followed.
Intellectual Property Security: Proprietary processes, designs, or formulas are shielded from industrial espionage by restricting access to the areas where sensitive information is handled.
Operational Efficiency: Modern systems can integrate with time-tracking, enabling smooth shift changes and monitoring workforce movement for efficiency.
Regulatory Compliance: Detailed logs of entries/exits help meet industry regulations (e.g., ISO standards, OSHA requirements) that demand tracking who accessed certain areas.

Types of Access Control Systems

Modern access control systems come in various types, often combining multiple authentication factors:

Keycard/Key Fob Systems: Employees use a card or fob (with magnetic stripe or RFID chip) to unlock doors. Swipe and proximity cards are common in manufacturing for controlling entry to buildings or rooms.
Biometric Systems: Utilise unique personal traits like fingerprints, iris scans, or facial recognition for identification. Biometric scanners are often placed at high-security checkpoints (server rooms, R&D labs) where positive identification is crucial.
PIN/Keypad Entry Systems: Require entering a numeric code on a keypad. These are simple and low-cost — often used at secondary doors or as a backup entry method.
Mobile Credentials: Allow access via smartphone apps or Bluetooth. Employees use their phones as a key, which is convenient for temporary access (contractors, visitors) and reduces the need for physical badges.
Multi-factor Systems: For sensitive areas, two or more credentials might be required (e.g., keycard + PIN or biometric + keycard) to add layers of security.

Each system has unique features. Keycard systems are ubiquitous and easy to manage, biometrics provide high security without cards, PIN pads add a basic layer of control, and mobile access offers flexibility. Often, manufacturing facilities use a combination: for example, key cards for general areas, biometrics for critical zones, and security personnel as a constant presence to oversee and respond.

Benefits and Challenges of Different Access Control Types

Implementing access control involves balancing convenience, cost, and security. Here are some benefits and challenges of different access control methods:

Biometric Systems: High security, accurate audit trails, no lost credentials, but high upfront cost, maintenance issues, and privacy concerns.
Keycard/Key Fob Systems: Proven and reliable, easy management, offline capability, but potential for misuse, ongoing costs, and credential management issues.
PIN Code (Keypad): Low cost and simple, no physical token needed, but minimal security, no individual log, and user friction.
Mobile Credentials: High convenience, remote management, reduced physical key costs, but connectivity dependence, cybersecurity concerns, and user adoption challenges.

Understanding each type’s pros and cons helps in choosing the right mix of technologies for your facility’s needs and risk profile.

Best Practices for Implementing Access Control in Manufacturing

Implementing an access control system effectively requires not just technology, but also policy and process. Here are actionable best practices to ensure a secure and efficient deployment:

Define Roles and Least-Privilege Access: Set up role-based access levels so employees only have access to areas necessary for their job.
User Provisioning Automation: Use software to automatically assign access based on role when onboarding new employees or contractors.
Multi-Factor Authentication (MFA): Implement MFA for sensitive access points.
Strong Credential Policies: Enforce password/PIN hygiene and periodic changes if keypads or software passwords are used.
Tiered Access Levels: Implement tiered permissions and assign people appropriately.
Visitor Management System: Control and monitor visitors with temporary badges or codes that expire.
Audit Trails and Monitoring: Ensure the system logs every access event and regularly review access logs for anomalies.
Integration with Surveillance: Link access control with video cameras for visual verification of entries.
Emergency Protocols: Plan how the system behaves in emergencies and train staff on these procedures.
Regular System Updates: Keep all access control software and firmware up to date.
Routine Maintenance: Schedule inspections of door hardware, readers, and backup batteries.
Employee Training and Awareness: Educate all facility personnel on access control policies and the importance of adherence.
Choose Reputable Vendors/Integrators: Work with experienced security system integrators who understand manufacturing needs.
Security Policies and Reviews: Document your access control policies clearly and perform regular security audits.

By following these best practices, a manufacturing facility can significantly reduce security lapses and ensure a robust access control implementation. The goal is to create a layered defence where technology, process, and people work together to secure the site.

Other blogs you may be interested in:

Case Studies and Examples of Successful Implementation

Real-world examples illustrate how manufacturing organizations benefit from well-implemented access control:

Biometrics in Pharmaceutical Manufacturing: A pharmaceutical plant upgraded from traditional access methods to a biometric access control system to secure critical production areas. Siemens installed over 40 fingerprint/iris biometric readers at entrances, connecting to a central access management software. This change improved security by ensuring only authenticated staff could enter sensitive cleanrooms. It also sped up shift changes — high-throughput biometric scanners reduced bottlenecks of staff waiting to clock in, improving productivity. The biometric system seamlessly integrated with the company’s IT network and compliance policies, showing how modern ACS can both enhance security and operational efficiency in manufacturing.

Mixed Technology & Tiered Access: Many factories use a layered approach. For example, an electronics manufacturing facility might use keycard access at the perimeter and main production floor but require a fingerprint scan to enter the R&D lab where new prototypes are designed. Visitors and contractors may receive mobile app credentials valid only for the day and only for non-sensitive areas. Meanwhile, security personnel monitor a central dashboard and cameras. Companies like those in the automotive or aerospace sectors often report improved loss prevention after implementing such tiered systems, along with easier compliance during security audits due to detailed logs.

Role of Integration – Automotive Plant Example: Consider a car manufacturing plant that integrated its access control with other systems. When an employee badged into a certain area, the system automatically could adjust the HVAC and lighting for that zone (an IoT integration that saves energy when areas are unoccupied). If someone attempted an unauthorised entry, alarms would trigger, and nearby CCTV cameras would automatically focus on that door. Over time, the plant saw not only improved security but also gains in efficiency (through automation) and easier investigations with synchronised access and video logs. This example shows the benefit of treating access control as part of a holistic smart security system.

Visitor Management Success: A large food processing factory implemented a digital visitor management system as part of its access control upgrade. Visitors sign in on a kiosk, take a picture, and receive a temporary RFID badge. This badge gives them access only to specific meeting rooms and corridors and expires after a few hours. Security staff are automatically notified if a visitor strays into unauthorised zones (as detected by door swipes). This system improved compliance with food safety audit requirements by providing a clear record that visitors never entered production areas. It exemplifies how combining access control with visitor logging heightens security and compliance.

Each case underlines common themes: combining technologies (cards, biometrics, mobile), the importance of precise access rules, and integrating human oversight. Successful manufacturing security often comes from this synergy of the right tools with well-designed policies.

Role of Security Personnel in Access Control

While electronic systems are vital, security personnel (guards) remain a cornerstone of effective access control in manufacturing facilities. Their roles include:

Identity Verification: Guards often staff entry gates or lobbies, where they check IDs, badges, or credentials. They provide a physical verification layer — ensuring the person using a badge is indeed the authorised holder, especially for high-security areas or during visitor sign-in.
Monitoring and Response: Security officers monitor the facility’s security cameras and access control dashboards in real time. If an alarm sounds (e.g., forced door, or an unauthorised attempt), they respond immediately by investigating or intercepting the person. Their presence is critical after-hours or in less-trafficked areas.
Managing Exceptions: In cases of system failures or special circumstances, guards can manually enforce access rules. For instance, during power outages they might secure doors, or during VIP visits they might escort and ensure temporary access is properly managed.
Policy Enforcement: Guards help enforce protocols like preventing “tailgating” (one person following closely behind another to sneak in). They may patrol entrances and remind or stop individuals who attempt to hold doors open or bypass the system. They ensure everyone, including employees and visitors, adheres to sign-in/out procedures.
Emergency Situations: In an evacuation or emergency, security personnel coordinate to unlock doors if needed, assist employees in exiting safely, and prevent re-entry until it’s safe. They also secure the site afterwards.
Training & Awareness: Often, security teams contribute to training employees on security awareness. They might run drills or distribute reminders about not sharing badges, reporting lost IDs, etc., supporting the overall culture of security.

In essence, security personnel are the human element that complements technology. They can make judgment calls in dynamic situations that automated systems cannot. For example, a guard noticing a suspicious behaviour can intervene even if the person used a valid badge. According to Equilibrium Risk experts, access control guards manage both physical entry points and electronic systems, verifying identities, monitoring surveillance feeds, and acting as first responders to any breaches. Their presence is also a deterrent; knowing that trained professionals are watching often discourages misconduct.

For manufacturing facilities, which may span large areas, security officers often cover perimeter patrols, gate checks for vehicles, and ensuring that areas like loading docks (where materials arrive and leave) are secured. Integrating well-trained security staff with advanced access control technology provides a balanced security posture, leveraging the strengths of both.

Integration with Other Security Measures

Access control systems become even more powerful when integrated into a broader security ecosystem. Manufacturing facilities should ensure their ACS can interface or work alongside the following:

Video Surveillance (CCTV): Integration with cameras is highly beneficial. When an access control event occurs (door opened or forced), the system can cue corresponding CCTV footage. Security personnel can visually verify identities or detect if someone piggybacked in. In case of an incident, synchronised logs and video provide a clear picture of events.
Intrusion Detection and Alarms: Doors or windows with sensors can tie into the ACS. For example, if a door is pried open without authorisation, an alarm sounds and alerts are sent via the access control platform. Conversely, during an alarm (fire alarm or security alarm), the ACS can be set to auto-unlock doors for safety or to facilitate response.
IoT and Building Management Systems: Modern ACS can integrate with IoT devices and building controls. One trend is using occupancy data from access control to adjust HVAC, lighting, or equipment. If no one has swiped into a zone for some time, lights can dim to save energy. If an area is suddenly occupied beyond normal capacity (many people swiping in quickly), ventilation or cooling can adjust. This integration improves safety (for example, ensuring proper airflow in a suddenly crowded space) and can reduce costs.
Time & Attendance Systems: Many factories use ACS data for payroll and attendance. Each badge swipe can log work hours (eliminating separate time clocks). This streamlines HR processes and reduces “buddy punching” (one employee clocking in for another) since access control usually has stricter identity verification.
Visitor Management & Identity Management: A good ACS should work with your visitor management software, as mentioned. Pre-registered visitors can be issued credentials in the ACS for the duration of their visit. Additionally, integration with corporate identity management (like an HR database or directory) means when someone’s employment status changes, their access rights update automatically (closing security gaps with departing staff).
Fire and Life Safety Systems: Ensure that the ACS is configured to cooperate with fire alarm systems. Many electronic locks are fail-safe (unlock on power loss or fire alarm) by design or can be overridden by fire systems. This integration is crucial so that access controls do not impede evacuation or emergency response.
Remote Monitoring and Cloud Management: Using cloud-based access control allows integration across multiple sites. For manufacturers with several plants, a centralised cloud platform can unify security management. Authorised security admins can adjust permissions, monitor alerts, and pull reports from anywhere. Cloud platforms also often integrate analytics or AI (e.g., sending a mobile alert to security if an anomaly is detected in access patterns).
Integrated security = comprehensive security. Combining access control with video surveillance and real-time monitoring provides a holistic solution: if an unauthorised access is attempted, cameras record it, and alerts notify managers immediately. By integrating systems, manufacturing facilities create redundancies and layers that a malicious actor would have to defeat all at once, which is far more difficult than defeating isolated measures.

When planning your access control implementation, consider existing systems and future additions. Opt for access control solutions with open APIs or known integrations so that as your security needs grow (adding new sensors, cameras, or analytics platforms), your access control can connect seamlessly. The end goal is a unified security infrastructure where everything “talks” to each other for maximum visibility and control.

Other blogs you may be interested in:

Technological Advancements in Access Control

The field of access control is continuously evolving, and keeping abreast of these advancements can help manufacturers enhance security and efficiency. Some notable technological advancements include:

Biometric Innovations: Biometric scanners are becoming faster and more accurate. Newer systems use multimodal biometrics (e.g., combining fingerprint and facial recognition) for higher accuracy. There are also contactless biometrics, like iris or facial scans, which are useful in sanitary or cleanroom environments.
Mobile and Wearable Access: The rise of mobile credentials means phones or even smartwatches can be used for access. NFC and Bluetooth Low Energy technology allow employees to just walk up to a door with their phone to unlock it. This is advancing towards hands-free access, improving convenience.
AI-Powered Access Control: Artificial Intelligence is being integrated to analyse access patterns. For example, AI can learn typical access behaviours and flag anomalies (if a normally day-shift worker tries to enter at midnight, or if an access is attempted at an unusual door for that user). AI can also assist in predictive security – forecasting potential insider threats by correlating unusual access with other data.
Cloud-Based Systems: As mentioned, cloud-managed access control is becoming popular. This offers advantages like remote system administration, easier scaling, and often better redundancy. Cloud systems frequently get faster updates and can integrate advanced features (like AI analytics) more readily.
Touchless Technology: Accelerated by health considerations (like pandemics), touchless access methods (mobile, wave-to-unlock sensors, facial recognition) have advanced. Manufacturing plants find this useful to minimize contact points (reducing contamination in clean environments or just germs in general).
Integration of IoT: Beyond connecting to existing alarms or CCTV, access control is part of the larger Industrial IoT trend. Smart sensors (motion detectors, occupancy sensors) can feed into access decisions. For example, if a motion sensor detects movement in a restricted room but no access was logged, the system could alarm immediately.
Blockchain for Access Logs: An emerging concept is using blockchain to secure access logs (ensuring logs can’t be tampered with). While not mainstream yet, it’s being explored for high-security environments to guarantee an immutable record of who accessed what and when.
Enhanced User Interfaces: Modern systems come with user-friendly dashboards, 3D maps of facilities showing access point status, and mobile apps for managers. These interfaces make it easier to administer and respond to security events quickly.
Predictive Maintenance: Access control hardware now sometimes includes self-diagnostic features. They can alert when a door lock is sticking or when a backup battery is low. IoT and AI together can predict failures in locks or sensors so they can be fixed proactively, ensuring uptime of the security system.

Staying updated on these technologies is part of future-proofing your security. Many manufacturers phase in new tech as budgets allow for instance, gradually adding biometric readers to the most critical areas, or moving to a cloud platform during a system refresh. The trend is toward more automation, intelligence, and integration. As one industry source notes, AI-driven systems can identify anomalies and alert managers in real time, and employees may soon use smartphones or even facial recognition in place of traditional badges. Embracing these advancements can give manufacturers an edge in security and sometimes even in convenience and cost-savings.

Regulatory and Compliance Considerations

Manufacturing facilities often operate under various regulatory frameworks that impact security and access control. Compliance considerations include:

Workplace Safety Regulations: Agencies like OSHA (Occupational Safety and Health Administration) require controlling access to hazardous areas (lockout/tagout procedures, etc.). An access control system supports such compliance by preventing untrained personnel from entering dangerous zones and keeping records of who entered high-risk areas.
Industry-Specific Standards: Certain industries have special rules. For example, pharmaceutical manufacturing must comply with FDA regulations (ensuring only authorised, qualified individuals access production areas of drugs). Food manufacturing might need to meet FDA/USDA or HACCP guidelines, where visitor logs and access restrictions help maintain sanitary conditions and traceability.
Data and Privacy Laws: Biometric data usage is subject to privacy regulations (like GDPR). If you use biometric scanners, you may need employee consent, clear data use policies, and secure storage of that data to comply with privacy laws. Ensure vendors provide features to support privacy (encryption, local processing, etc.).
ISO Standards: Many manufacturers pursue ISO 9001 (quality management) or ISO 27001 (information security) certifications. While ISO 9001 might indirectly relate (through facility management and training), ISO 27001 explicitly covers physical security of facilities. Effective access control with audit logs can help satisfy some ISO 27001 controls. There are also ISO standards for access control (like ISO/IEC 60839-11 for electronic access control systems) that, while technical, ensure interoperability and reliability.
Audit and Record-Keeping Requirements: Some regulations require maintaining records of access. For example, pharmaceutical and chemical industries might need to show an audit trail of who accessed storage of controlled substances or hazardous materials. Access control logs, when preserved, serve as evidence of compliance. Automated record-keeping by ACS makes compliance easier, as noted, providing reliable data for audits.
Visitor and Contractor Controls: Regulations may also mandate controlling non-employee access. For instance, certain defence contracts require strictly controlling visitor access to manufacturing sites. A combination of background checks, escort requirements, and access control credentials for visitors may be needed.
Fire and Building Codes: Beyond security, local building codes influence how access systems are installed (e.g., doors must allow emergency egress without special knowledge or tools – often satisfied by crash bars that override locks). Access systems must be configured to comply with life safety codes (NFPA standards, etc.) to ensure people can exit quickly in emergencies. Usually this means fail-safe locks and clearly marked exits.
Compliance Tip: When designing your access control system, involve your company’s compliance officer or consult relevant regulations to ensure the system’s configuration and policies align with legal requirements. For example, ensure your system has the capability to archive access logs for a required period if an auditor might ask for six months of entry records. Or, if using biometrics, implement a procedure for obtaining and storing consent forms.

Ultimately, a well-implemented access control not only protects the facility but also helps demonstrate diligence to regulators. Many regulations and standards see robust physical security as part of risk management. By meeting these through ACS, manufacturers avoid penalties and reinforce their reputation as safe, secure operations.

Compliance should be seen as a baseline – meeting the rules – whereas best practices may even exceed minimum requirements for greater security.

Other blogs you may be interested in:

To explore how to approach the financial aspects of access control systems, including key budgeting strategies and cost breakdowns, continue to part 2 of this blog. Understanding the investment required for various technologies can help you make informed decisions that align with your security needs and operational goals.

Are thinking of implementing Access Control in your manufacturing facility? Our PREPARED methodology offers a comprehensive cyber-physical security solution tailored specifically for manufacturing environments. Find out more here.

This content has been generated with the assistance of artificial intelligence (AI). While AI technology was used to draft and develop the initial content, it has been thoroughly reviewed, edited, and fact checked by Luke to ensure accuracy and relevance. We strive to provide high-quality and trustworthy information, but please be aware that AI-generated content may contain errors or omissions. We take full responsibility for the final content presented here and are committed to maintaining transparency and integrity in our use of AI technology.