1. Client Snapshot

A Fortune-500 integrated metals & mining group operating three high-throughput smelter-and-power campuses in India. Each site sees 1,500–2,000 visitors and contractors per day across multiple gates.

2. Operational Headaches

Challenge

Why It Hurt

Paper Logbooks

Manual registers delayed entry, created illegible records and produced no real-time headcount.

Long Queues

Average gate wait-time reached 5–7 minutes at shift change, impacting production start-ups.

Ad-hoc Safety Induction

Language barriers meant critical safety messages were often skipped or poorly understood.

Audit-Trail Gaps

Compliance teams spent days reconciling visitor logs for ISO & DGMS audits.

Isolated Biometrics

Existing fingerprint scanners tracked only employees, not contractors or guests.

3. Project Objectives

Reduce gate processing time to < 90 seconds per visitor.
Achieve a 100 % digital, audit-ready trail for every person on-site.
Deliver multi-language safety induction before the visitor reaches the gate.
Integrate the new Visitor Management System (VMS) with existing biometric turnstiles for a single source of truth.

4. Digisailor Solution

Pillar

Key Components

Cloud VMS Platform

Central web console, high-availability SaaS architecture.

Pre-Visit Workflow

Role-based invitations via SMS/e-mail → secure link for ID upload, multilingual safety video, e-signature.

Smart Pass Generation

Auto-generated QR + numeric PIN, valid only for approved date/time and zone.

On-Site Hardware

Android tablets at guard posts; seamless link to existing fingerprint & facial-recognition turnstiles.

Real-Time Dashboards

Live head-counts, zone occupancy, expiring passes, compliance KPIs.

Analytics & Reporting

One-click exports mapped to ISO 45001 / internal audit templates.

5. Biometric Integration Highlights

Single Credential – Visitors scan the QR at a tablet; the system instantly pushes a temporary biometric record to the turnstile, allowing fingerprint/facial authentication without manual enrolment.
Dual-Factor Security – Entry is granted only when both the QR check-in and biometric match succeed, eliminating tailgating.
Unified Audit Logs – VMS and biometric events are merged into a single timeline, so HSE and Security teams no longer juggle multiple databases.
Auto-Expiry & De-Provisioning – Temporary biometric profiles are purged automatically at pass expiry, maintaining data privacy compliance.

6. Implementation Roadmap

Phase

Duration

Milestones

Process Mapping

2 weeks

Current-state analysis, SOP alignment, data-flow design.

System Configuration

3 weeks

Invitation templates, induction content, zone & user roles, API connectors for biometrics.

Pilot Roll-Out

4 weeks

One gate per site, feedback loop with Security & HSE teams.

Scale-Up & Training

2 weeks

Full multi-gate deployment, staff train-the-trainer sessions, cut-over.

7. Measurable Impact

Metric

Before

After

Improvement

Manual Onboarding Steps

-80 %

Average Gate Wait-Time

5–7 min

< 90 s

-70 %

Audit Preparation Time

3 days / audit

< 4 hours

-85 %

Gate Paperwork

100 %

0 %

Paperless

Data Accuracy (Logs)

~65 %

99.9 %

+54 ppt

Figures based on a three-month post-deployment study across all campuses.

8. What Made the Project a Success?

User-Centric Design – Guard screens limited to two taps; visitors finish induction on their own phones.
Zero-Downtime Integration – Biometric API link implemented without replacing existing turnstiles.
Scalable Architecture – Multi-tenant cloud handles up to 10,000 concurrent passes/day.
Multilingual Compliance – Induction videos in English, Hindi, Tamil and Odiya ensured 100 % comprehension.

9. Client Quote

“Our gates went from paper chaos to scan-and-go. The biometric sync means every person—employee, contractor, or VIP—follows the same secure, compliant flow.”

— Head of Security & Compliance

10. Looking Ahead

Contractor Workforce Analytics – Expansion of dashboards to track cumulative contractor man-hours vs. safety KPIs.
Geo-Fencing – Planned BLE beacon integration for zone-level occupancy tracking inside production blocks.
API Ecosystem – Upcoming connectors to ERP for automated invoicing tied to actual contractor site time.

11. Key Takeaway

By fusing Digisailor’s cloud VMS with existing biometrics, the client eliminated paper, cut queues by 70 %, and gained real-time, audit-ready visibility—all without cap-ex on new access-control hardware. If your organisation battles gate congestion and compliance risk, our plug-and-play VMS blueprint can deliver the same rapid ROI.

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