Registered Office
Registered Office - Silbar Security Services Pvt. Ltd.
5th Floor, Statesman House, Plot No. 148, Barakhamba Road, Connaught Place, New Delhi — 110001
+91 99821 70555Mon–Sat: 9:00 AM – 7:00 PM
CASE STUDY
Manufacturing Plant Security Overhaul
Leading Automobile Manufacturer · Rajasthan
The Challenge
Unchecked Losses Across Three Factory Units
The client operated three adjacent manufacturing units in Rajasthan's industrial belt, producing auto components for both domestic OEMs and export markets. Despite having a security contract with a previous vendor, the plant had been experiencing persistent material theft — copper wiring, aluminium scrap, and finished inventory worth over ₹85 lakhs had gone missing in the preceding financial year alone. Internal investigations pointed to collusion between contract guards and truck operators at the material dispatch gates.
Broken Access Control and Shift Gaps
The factory perimeter spanned 22 kilometres, with six entry points. Access control was limited to manual logbooks at two main gates; the remaining four gates were either unmanned or staffed by a single guard with no vehicle search protocol. Visitor verification was non-existent — anyone claiming vendor status could walk in. Night shifts operated with skeleton coverage, and three separate security incidents involving unauthorised entry into the tooling section had been recorded but never acted upon.
High Attrition and Low Morale
The previous vendor's guards had not received salary increases in three years. Attrition was running at 45% annually, meaning the client saw a new guard every few weeks. Training records were fabricated for audit purposes, and guards on site could not demonstrate basic knowledge of fire extinguisher operation or first aid. The client's internal audit flagged 37 non-compliances across the three units, including missing PSARA documentation and expired EPF remittances.
The Solution
Risk Assessment and Site-Mapped Deployment
Silbar Security Services Pvt. Ltd. began with a two-week risk assessment across all three units. Our team mapped every entry and exit point, analysed material movement patterns across shifts, reviewed existing CCTV coverage gaps, and interviewed plant supervisors to understand pain points. The assessment report identified 14 critical vulnerabilities, including the four unguarded gates, unsecured scrap yards, and the absence of material gate pass systems. Based on this, we designed a three-zone security architecture with dedicated guard posts, roving patrols, and CCTV integration.
Deployment of 135 Trained Personnel with Modern Protocols
We deployed 135 security personnel across the three units — including 14 supervisors, 8 lady guards for the female worker entry points, and a dedicated field officer per shift. Each guard completed a seven-day induction covering access control, vehicle search procedure, material gate pass verification, and fire safety. We installed a biometric attendance system linked directly to our central control room to prevent buddy punching. Gate management was overhauled: every vehicle entering or leaving is now logged through our Material Gate Pass system with photographs, weight slips, and supervisor sign-off.
Technology-Enabled Monitoring and Compliance Assurance
We integrated 48 new CCTV cameras with the client's existing system, covering all blind spots identified in the assessment. A dedicated monitor wall was set up in the plant security office. Our remote monitoring centre in Jaipur provides 24/7 oversight of critical feeds. On the compliance front, we regularised all statutory documentation — PSARA licensing for Rajasthan, EPF/ESIC registration for all deployed staff, and weekly training records. Monthly audit reports are submitted to the plant head with incident summaries, patrol compliance scores, and improvement recommendations.
Results Delivered
70% reduction in material theft within the first six months
Zero security breaches in the subsequent 12-month period
25% cost optimisation vs previous vendor through consolidated deployment
100% statutory compliance achieved across all three units
Guard attrition reduced to under 12% annually through better wages, accommodation, and career progression
All 37 previous audit non-compliances closed within 90 days
Client Testimonial
“Silbar transformed our security from a constant worry into a reliable operation. The theft numbers that were bleeding our bottom line have completely stopped. Their quarterly business reviews keep our leadership team informed and confident.”
Vikram RathorePlant Director, Automobile Manufacturing Division
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