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.
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.
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.
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.
After the new system was stationed, onboarding became significantly simpler. The homemade way was reduced from 10 to just 2, marking an 80% reduction in trouble. This streamlined approach not only saved time but also bettered the overall stoner experience.
At the gates, waiting times dropped drastically. What once took 5–7 minutes on average was reduced to less than 90 seconds, cutting delays by nearly 70%. This improvement ensured smoother entry flows and minimized production disruptions during shift changes.
Inspection medication also came far more effective. Preliminarily, brigades spent around three full days preparing records for each inspection. With the new system in place, the time needed dropped to less than four hours—an 85% enhancement. This meant compliance checks were brisk and less resource-intensive.
Gate paperwork, once a 100% manual burden, was eliminated. The process became fully paperless, enabling faster data handling and eco-friendly operations.
Most importantly, data accuracy improved dramatically. Log reliability increased from around 65% to 99.9%, a gain of 54 percentage points. This accuracy boost ensured trustworthy records for audits, compliance, and day-to-day operations.
These figures are based on a three-month post-deployment study conducted across all campuses, clearly demonstrating the transformative impact of the solution.
“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
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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