A pharmaceutical manufacturing campus in Haridwar with three production blocks, a warehouse and an administrative block was facing a serious security and compliance challenge. The campus had no systematic personnel inspection at entry — bags and personnel were not screened, creating a risk of prohibited items (mobile phones, lighters, recording devices) entering production zones — a Schedule M GMP compliance violation. Finished goods theft had been identified as a recurring problem: audit reconciliation had flagged a cumulative discrepancy of ₹22 lakhs over 12 months in finished goods inventory, but without screening records, it was impossible to identify the point of leakage. Additionally, the company's product liability insurer had formally recommended installing vehicle screening at the entry gate as a condition for renewing the transit goods insurance policy. Management needed a complete, documented inspection framework deployed within 8 weeks.
Multi-Layer Personnel & Vehicle Inspection System for a Pharmaceutical Manufacturing Campus
Pujaso designed a three-layer inspection architecture covering all personnel and vehicle entry and exit points.
Layer 1 — Main Gate Vehicle Inspection: An ANPR (Automatic Number Plate Recognition) camera was installed at the main vehicle entry and exit gates. All entering and exiting vehicles are logged automatically with timestamp, direction and number plate image. A manual inspection checklist app was configured for the gate guard — for goods vehicles, the guard records vehicle number, driver details, goods description and weighbridge slip number. A magnetic under-vehicle mirror trolley was deployed for security inspection of goods vehicles before entry.
Layer 2 — Building Entry Personnel Inspection: DFMD walk-through metal detectors were installed at the entry to all three production blocks. Security personnel conduct HHMD secondary screening for positive alerts. Prohibited item policy was printed and displayed at each checkpoint: no mobile phones, no lighters, no metal tools beyond the check point without authorisation.
Layer 3 — Dispatch Bay Outbound Inspection: A baggage X-ray conveyor was installed at the dispatch bay exit — all personal bags, tiffin boxes and carry items of outgoing personnel are scanned before leaving the production and warehouse area. The X-ray system includes automatic detection algorithms for dense items that may indicate concealed goods.
All inspection logs were integrated into a central security reporting dashboard. Daily reports are generated showing: vehicles entered/exited, number of personnel screened, DFMD alerts raised and secondary screenings conducted.