GMP-Compliant Access Control & Biometric Attendance for a Pharma Facility

A pharmaceutical manufacturing facility in Baddi was preparing for a regulatory inspection under Schedule M GMP requirements. Two areas of concern identified in a pre-inspection audit: access control for production zones lacked electronic verification (posted guards were the only control, with no audit trail) and the attendance system — punch cards — had documented inaccuracies that would not withstand regulatory scrutiny. The facility needed electronic access control with a complete zone-entry audit trail and a biometric attendance system integrated with SAP HCM payroll, all deployed and validated before the inspection date 8 weeks away.

Pujaso proposed and delivered a ZKTeco-based solution in a 5-week implementation with a 1-week validation period before the inspection.

22 ZKTeco face recognition terminals were installed at all production zone entries: granulation, compression, coating, packaging (8 terminals), quality control laboratory (4 terminals), weighing and dispensing area (3 terminals), store and quarantine (4 terminals), and administrative block (3 terminals). Each terminal was configured with zone-specific access lists by job role — production operators, QC analysts, supervisors and managers each have appropriate access levels.

The attendance module was activated on all 22 terminals — first IN and last OUT per day recorded automatically, with all intermediate zone movements logged. SAP HCM integration was configured via the ZKTeco API — attendance data syncs to SAP every 30 minutes. Shift schedules, overtime thresholds and leave types were all configured to match the existing SAP payroll structure.

40 Hikvision cameras were installed in production areas, corridors and external zones to provide visual audit coverage alongside the electronic access log.