Implementing Access Control Systems in Manufacturing: Best Practices - Part 2

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, CCTV, Perimeter, Guarding, Access control, Intruder alarm

After exploring the critical role of access control systems (ACS) in ensuring compliance and operational safety, part two delves into the practical considerations tied to implementing these systems.

From the financial investment to the technological choices, it covers the key factors manufacturers must evaluate to establish robust and cost-effective security solutions tailored to their unique facilities.

Cost Considerations and Budgeting for Access Control

Implementing access control in manufacturing is an investment. Costs can vary widely based on the size of the facility, number of access points, and technologies chosen. Key cost components include hardware, software, installation, and ongoing maintenance. Here’s a breakdown:

Typical Cost per Door by System Type: (estimates for hardware & basic installation per access point)

Keypad (PIN code): £800 – £2,000
Keycard/Fob (Reader + Card): £1,200 – £2,800
Mobile/App-Based Access: £1,600 – £3,600
Biometric (e.g. Fingerprint): £2,800 – £8,000+

Note: These ranges include typical reader hardware and basic installation. Higher-end or specialised equipment (e.g., a multi-factor reader that supports card + fingerprint) would be on the higher side. A state-of-the-art biometric system can indeed exceed £10k per door when considering high-quality sensors.

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Additional cost factors:

Installation and Wiring: The labour and materials to install door hardware, run cables for readers and controllers, etc. can add can add £400–£1,600 per door depending on complexity (retrofitting old doors, long cable runs, etc.).
Software and Licensing: Many enterprise access control systems require a central management software. This might be a one-time purchase or a subscription (especially cloud-based ones). Costs can be £0–£40 per door per month for software/service. Cloud systems often have ongoing subscription fees, whereas on-premises might have a larger upfront license cost plus optional support contracts.
Credential Costs: Keycards or fobs cost money (£5–£10 each typically). Biometric systems avoid card costs but might have costs for enrolling users (time/labour). Mobile credentials can have licensing costs per user in some systems.
Maintenance: Consider ongoing maintenance like software updates (if not covered in subscription), replacing faulty readers (over years, readers/keypads wear out), and support. Some vendors offer maintenance contracts. Also, battery replacements for wireless locks or UPS systems for controllers are a minor recurring cost.
Integration and Upgrades: If integrating with other systems (HR database, CCTV), there might be one-time setup or customisation fees. Budget a margin for unexpected integration tasks or future upgrades (perhaps ~10-15% of project cost).
Security Personnel Training: If new systems are introduced, some budget might go into training security staff or IT staff to administer the system effectively (not a hardware cost, but a project cost).
Economies of Scale: Note that per-door costs often decrease as the number of doors increases, due to shared infrastructure. A single-door setup must include the controller and software, whereas a 20-door setup shares those costs across many entries.

When budgeting, prioritise critical areas first. Many firms implement access control in phases: secure the most sensitive zones and main perimeter first, then expand. This spreads cost over time and allows learning and adjustment.

Example Budget Scenario: A medium-sized plant with 10 controlled doors might choose a mid-range keycard system. Using the table above, hardware might be ~£1,600/door including reader and lock, totalling £16,000. Installation could add £8,000. Software license for 10 doors might be £2,400 initial or £80/month cloud subscription. So, initial implementation perhaps £24k–£28k. If biometric on some doors, those might cost double per door, raising totals accordingly. It’s important to also quantify the benefits (reduced theft, better compliance, possibly lower insurance premiums) to justify the ROI.

Cost-Benefit Tips:

Sometimes insurance companies offer better rates for facilities with certified security systems; check if an ACS can reduce insurance costs.
Factor the potential losses prevented (one major theft incident could cost more than the system’s price).
Consider scalable solutions – maybe start with keycard locks and later upgrade some to biometric as needs grow, using a platform that supports both (hybrid systems exist).
Budget for the lifetime, not just installation. A system might last ~5-10 years before major upgrades, so consider total cost of ownership (TCO) including maintenance and eventual replacement or expansion.

By carefully planning and comparing options, manufacturers can achieve a balance between security needs and budget constraints. The goal is not always to buy the most expensive system, but the one that fits your risk profile and operational needs cost-effectively. At Equilibrium Risk, we conduct a security audit with our proposal, which can be useful to gauge the budget required. Remember, a well-implemented access control system is an investment in protecting the business – it can pay back by preventing costly incidents and by improving processes.

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Training and Maintenance of Access Control Systems

Once an access control system is in place, ongoing training and maintenance are vital to ensure it continues to perform effectively and securely.

Training for Employees and Staff:

Operator Training: Security personnel and system administrators should receive detailed training on the access control software and hardware. They need to know how to add/remove users, adjust permissions, respond to alarms, pull reports, etc. Proper training ensures the system’s features (like report generation or remote management) are fully utilised.
Employee Awareness: Regular employees should be briefed on new procedures. For instance, if biometric scanners are introduced, educate users on how to properly place a finger or that they should report any skin condition that might affect scanning. If using cards, remind them not to share cards or tailgate. Training can be done during onboarding and refreshed yearly. As one best practice, train employees on access control policies and encourage reporting of suspicious activities. People are more likely to follow rules when they understand the reasons (safety, security) behind them.
Drills and Testing: Conduct periodic drills or tests. For example, simulate a scenario where someone without proper access tries to enter, and test if staff respond correctly (this can be part of security audits). Or test emergency exits with the system (without real danger) to ensure everyone knows procedures if doors lock or unlock automatically.
Update Training for Changes: When system updates or policy changes occur (say you add multi-factor at a certain door), communicate this and train relevant users. Keep user guides or quick-reference instructions available, especially for less intuitive actions (like how to use a mobile credential app).

Maintenance Practices:

Regular Inspections: Schedule routine checks of all physical components: door locks (do they latch securely?), readers (are they clear of dust/grease and working properly?), sensors and emergency exit buttons. Manufacturing environments can be harsh (dust, vibration), so more frequent inspection might be warranted.
Software Updates and Patches: As mentioned earlier, apply updates to firmware and software promptly. Many modern systems will alert administrators to available updates. Ensure you have support contracts or access to downloads from the vendor. If the system is on a network, coordinate with IT to keep it cyber-hardened (firewalls, etc.).
Backup Management: Keep backups of the access control configuration and database (user credentials, logs). Ideally, have a backup power (UPS) for the main controllers so that a power outage doesn’t corrupt the system or lock everyone out unexpectedly. Test backups and redundant systems periodically.
Calibration and Cleaning: Biometric devices may need occasional calibration (for example, adjusting sensitivity) as recommended by the manufacturer. All readers (card or biometric) should be kept clean – e.g., a fingerprint scanner might need the platen cleaned to read properly. In industrial settings, grime can accumulate, so include this in janitorial or maintenance routines.
Review Access Rights Regularly: This is more of an administrative maintenance: conduct reviews (perhaps quarterly or semi-annually) of who has access to what. Remove any “access creep” where someone accumulated permissions they no longer need. This administrative upkeep is essential to maintain the principle of least privilege over time.
Monitor System Health: Many systems have dashboards for door status or connectivity. Ensure all doors are communicating—if a door goes offline, address it immediately (could be a cut cable or a failed device). Some software can send alerts if a component fails or a battery is low—heed those.
Service and Repairs: Have a plan for who fixes issues. It might be on-site maintenance staff or an external contractor. Don’t leave broken card readers or door sensors unattended; they can become weak points. If a part is under warranty or service contract, arrange timely repairs or replacements.
Documentation: Maintain documentation of the system configuration and any changes. This helps in troubleshooting and is useful info for new team members or vendors assisting you. Also, log maintenance activities and incidents—like how one would log machine maintenance on the production line.
Continuous Improvement: Finally, treat the access control system as a living part of the facility. Learn from any security incidents or near-misses to improve. For example, if tailgating becomes an issue at a shift change, you might need to retrain staff or add a secondary door or a guard at that time. If an audit finds missing log data, adjust procedures to ensure logs are kept properly.

In summary, well-trained people and well-maintained equipment go together to keep an access control system effective. Skimping on training can lead to user errors that undermine security (like propping doors open). Neglecting maintenance can result in system failures that attackers might exploit (or just cause costly downtime). Dedicating time and resources to these areas ensures you get the maximum-security benefit from your investment in access control technology.

Future Trends in Access Control for Manufacturing

Looking ahead, several future trends are poised to shape how access control is implemented in manufacturing environments:

AI and Machine Learning: As discussed, AI will play an increasing role. Future ACS may autonomously adjust access rules based on learned behaviour patterns or integrate with HR systems to predict insider threat (e.g., unusual behaviour by a disgruntled employee). AI could also optimise operations by analysing traffic patterns through doors to suggest workflow improvements.
Convergence of Physical and Cyber Security: Access control data might integrate with cybersecurity. For example, if someone badges into a building, only then are they allowed to log into the workstation (tying physical presence to digital access). In manufacturing, this could protect sensitive control systems—ensuring that only an on-site engineer can log into a production system.
Biometrics Everywhere: Biometric authentication may become standard, not just for high security. Costs are gradually decreasing. We might see multi-biometric systems, like requiring both face and fingerprint for extremely sensitive areas (making spoofing nearly impossible). Additionally, more privacy-preserving biometrics (e.g., templates that can’t be reverse-engineered to the original fingerprint image) will ease concerns, making adoption smoother.
Mobile-First Access: The smartphone’s role is growing. Future systems might do away with physical ID badges entirely. Everything may be managed through apps with secure cryptographic keys. The phone itself might use its biometrics (fingerprint or face) to unlock the credential. Also, with UWB (ultra-wideband) technology, very precise location-based access may be possible (doors unlocking as an authorised phone comes within a few feet).
Cloud Ecosystems and Unified Platforms: As companies adopt cloud services, access control could merge with other cloud-based facility management tools. Unified dashboards controlling security, lighting, HVAC, and even production IoT devices might come into play. This holistic management can improve response times and decision-making.
Regulatory Pressure and Standards: We may see stricter regulations requiring certain levels of access control for critical infrastructure or manufacturing in sensitive sectors (like semiconductor fabs or food and pharma supply chains). Compliance requirements could drive adoption of advanced access systems in smaller companies too, not just large enterprises.
Green and Sustainable Security: An emerging consideration is energy efficiency. Future ACS hardware might be more energy-efficient or even energy-harvesting (wireless locks that self-charge via solar or kinetic energy). Sustainability goals could drive more wireless, battery-efficient deployments, and using access data to reduce power usage (as mentioned in integration, turning off lights when areas are unoccupied).
Enhanced Visitor and Contractor Management: With more focus on supply chain security, expect improved systems for managing third-party access. We might see temporary access credentials delivered via SMS to a visitor’s phone that only activate at the appointment time, or geofenced credentials that only work at one site.
Augmented Reality for Security Personnel: Looking further out, security guards might use AR glasses that show real-time data — when looking at a door, the glasses display if it’s locked or the last person who badged through. This kind of technology could increase the effectiveness of roving security patrols on the manufacturing floor.

The manufacturing sector’s security needs will continue to evolve, especially as Industry 4.0 (smart factories) becomes the norm. Every new internet-connected machine or sensor is a potential endpoint to secure. Thus, physical access control might merge with logical (IT network) access control in the concept of “Cyber-Physical” security.

One clear indication of the growth in this area: the global industrial access control market was valued at approximately £2.82 billion in 2023 and is projected to grow at 8.4% CAGR through 2030. This growth is driven by rising security threats and the availability of new solutions.

It underscores that manufacturers are investing in access control not just as a protective measure but as a strategic component of operations.

Staying Future-Ready: To prepare, manufacturers should design current systems with flexibility and scalability in mind. Choose vendors known to innovate, and systems that can be expanded or upgraded easily. Keep an eye on industry developments via security conferences or industry groups. Many companies form internal cross-functional teams (IT, security, operations) to regularly review security tech advancements. By doing so, you ensure that as new threats emerge or new tech becomes viable, your facility can adapt and remain secure and efficient.

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Conclusion

Implementing access control systems in a manufacturing environment is a multifaceted effort that combines technology, people, and process. From the basic premise of keeping the wrong people out and letting the right people in, we’ve seen that modern access control encompasses biometric scanners, keycard/fob systems, PIN pads, and mobile credentials, each with their own strengths. The best practices — like enforcing least privilege, maintaining audit logs, integrating with surveillance, and training employees — form the backbone of a secure deployment.

Crucially, a manufacturing facility should not rely on technology alone: security personnel play an indispensable role in monitoring and responding to incidents, and their partnership with electronic systems creates a resilient security posture. Moreover, the most effective solutions treat access control not as an isolated system but as part of an integrated security framework, linked with cameras, alarms, and IT systems for a comprehensive approach.

Considering costs and maintenance ensures that the system remains sustainable and functional year after year, while attention to regulatory compliance ensures that the security measures also meet legal and industry standards. And as the industry evolves, embracing new advancements and future trends like AI, mobile integration, and improved biometrics will help manufacturing facilities stay one step ahead of potential threats.

In essence, access control in manufacturing is about creating a safe, secure, and efficient working environment. It protects not just physical assets, but also the well-being of employees and the integrity of the products and intellectual property being created. By following the guidelines and best practices detailed above, and by remaining vigilant and adaptive, organisations can significantly reduce security risks. The result is a manufacturing operation where security processes run smoothly in the background, enabling the business to focus on productivity and innovation, with confidence that its people and assets are well protected.

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.