5.1 Physical Security & Access Control

Physical security in manufacturing is not about theft prevention; it is about preserving the "Chain of Custody" for client Intellectual Property (IP). A breach here compromises not just inventory, but the contractual integrity of the entire operation. Treat facility access as a layered filtration system—each zone requires a higher authentication friction to enter, ensuring only validated personnel interact with sensitive assets.

Access Control Architecture (Zoning)

Define your facility by risk, not by department. Movement between zones must be physically restricted and digitally logged.

• Zone 1: Public/Admin (Lobby, Offices)
  • Access: Standard RFID Badge.
  • If Visitor/Contractor arrives -> Then Issue "Escort Required" badge (Red/Yellow).
    • Constraint: Visitors must remain within 2 meters of their host at all times.
• Zone 2: Production Floor (SMT, Assembly)
  • Access: RFID Badge + Anti-Passback logic.
  • Physics: Anti-passback prevents a badge from entering twice without an exit scan, stopping "Tailgating" where one badge grants entry to multiple people.
• Zone 3: Restricted (Server Room, High-Value Cage)
  • Access: Multi-Factor Authentication (MFA). RFID Badge + Biometric (Fingerprint/Iris).
  • Rule: No single credential is sufficient for high-risk assets.

Pro-Tip: Install door contact sensors on all perimeter and Zone 3 doors. Program the access control system to trigger a "Door Forced / Door Propped" alarm if the contact remains open for > 30 seconds.

Surveillance (CCTV) Standards

Cameras are forensic tools, not live monitors. Their value lies in the ability to reconstruct an event frame-by-frame.

• If Area is Loading Dock / Entry -> Then Camera must capture facial ID and License Plates.
• If Area is High Value (The Cage) -> Then Resolution must be 4K (8MP) to capture part numbers on labels.
  • Retention: Store footage for ≥ 90 Days on RAID arrays. A 30-day loop is insufficient for investigating inventory shrinkage discovered during quarterly audits.

High-Value Asset Storage ("The Cage")

CPUs, FPGAs, and Memory modules represent dense value. Store them in a physical enclosure that is harder to breach than the facility itself.

• If Accessing The Cage -> Then Enforce the Two-Person Rule.
  • Logic: Two badges must scan simultaneously to release the lock. This forces collusion, significantly raising the barrier for internal theft.
• If Inventory is Top 10 Value SKUs -> Then Perform Daily Cycle Count.
  • Action: Resolve discrepancies before the shift ends.

IP Protection & Imaging

• If entering Zone 2 (Production) -> Then Personal smartphones and cameras are Strictly Prohibited.
  • Action: Store devices in Zone 1 lockers.
• If CCTV views Monitors -> Then Apply Privacy Masks.
  • Requirement: Cameras must not record CAD data, schematics, or BOMs displayed on screens.

Final Checklist