From Frustration to Control: A Manufacturing Plant’s Security Overhaul with Verkada

With hundreds of moving parts, constant activity, and valuable equipment, this manufacturing plant needed a reliable way to monitor its daily operations. But instead of confidence, the outdated security system left the team frustrated and vulnerable. “The hardware and systems that had been implemented 7-8 years ago were failing and/or having regular issues, and getting support for those systems, especially trying to manage them, was very, very cumbersome,” said Mike Rollins, Account Manager and Sales Engineer at VLCM. The outdated cameras, hard-to-retrieve camera footage, and on-site management meant that security was more of a hassle than a safeguard.

The plant, which operates a large manufacturing floor, warehouse, and office space, had been using an on-premises security system that could not be managed remotely. This system relied on local servers, and the cameras often suffered from quality issues and downtime. It was a setup that made security oversight a challenge, especially when incidents occurred during off-hours.

The client’s local team faced a tough obstacle: accessing footage. When an incident happened, whether it was an accident in the plant or an unauthorized access attempt, someone had to physically be on-site to retrieve camera footage. “Video surveillance was managed locally by the staff - not by a security team - and it made things difficult for them because they’re often remote—they’re not always in the office,” Mike explained. “When they had issues, they’d have to come on-site to pull up video from cameras, and a lot of times cameras might be down, or the video quality wasn’t very good.”

The time-sensitive nature of security footage often added to the frustration. “When they were asked to retrieve camera footage, not only was it difficult to get to it, but then accessing it and finding the particular window or timestamp on the incident was very difficult,” Mike added. Imagine driving to the site at odd hours, unsure if the footage you need is available or usable. This was a major pain point for the team, and it became clear that their old system wasn’t just outdated—it was a liability.

The Shift to Verkada: Cloud-Based Security

The tipping point came during one such incident when the camera server began failing. It was then that the conversation about upgrading began in earnest. “When the most recent incident came up a couple of years ago, where they were having issues with the camera server and getting support from the manufacturer, the IT director and I started having conversations about moving away from their legacy system,” Mike said. They discussed moving to a cloud-based system that would be easier to manage remotely, with better access to footage. Moving away from the old, on-premise setup was very appealing. The client was ready for something new.

“Verkada sent a demo camera out for the client to install and test,” Mike continued, “we also spun up Verkada Command, a platform where they can control and access the cameras from anywhere.”

It wasn’t long before the benefits of the new system became clear. “I think the client instantly realized how great it was because not only was the camera providing much better video, but he could also access camera footage from anywhere—any type of web UI. He could do it on his phone, from his laptop, or even from his home PC,” Mike explained. Gone were the days of driving to the facility late at night to physically retrieve the footage. Now, it was all accessible with just a few clicks, no matter where the team was. Cameron Bagley, VLCM’s Cabling Technician, added, “You can even email or text a link to the camera footage to other staff members. It can be done in a minute.” 

Mapping Out the Solution

With the demo's success, the client fully committed to Verkada. They didn’t just want to replace a few cameras—they wanted to ensure they were getting the best surveillance coverage with this installation.

VLCM and Verkada conducted multiple walkthroughs to assess camera placement throughout the plant, warehouse, and office spaces. “We made recommendations on camera types and coverage areas. We weren’t only replacing legacy cameras; we also added cameras in key areas throughout the facility,” Mike said. These new cameras ensured comprehensive coverage, addressing previous blind spots in the building’s security setup.

In total, 33 cameras were installed for the project, both inside and outside the facility, with cameras placed strategically to monitor key areas such as entry points, the plant floor, and warehouse spaces. “We did multiple walkthroughs to identify existing camera locations. We also had to verify that the ethernet cabling to each of the camera endpoints was good. Some new wiring was installed, and some existing wiring was rerouted in certain locations. Then, the physical implementation involved installing mounting hardware, setting up the cameras, and commissioning them,” Mike explained.

The entire installation took about a week and a half. During the process, VLCM ensured that everything—from cabling to camera placement—was handled smoothly, thanks in part to Cameron’s technical expertise. “Cameron’s a very capable technician, great at problem-solving. His experience helped make the implementation a lot smoother,” Mike added.

Expanding to Access Control

Once the client had settled into the new video surveillance system, they began to see additional possibilities for improving their facility’s security. Verkada’s Command platform not only manages video surveillance, but it can also support Verkada access control, alarms, and more - all through a single interface. It was an easy decision for the client to upgrade their access control system as well.

“The idea that they could manage not only video surveillance but access control, alarms, and other systems through Verkada Command was very appealing. So, within a few months, they asked us to come in and replace all of their card readers in the building, adding Verkada control inside and Verkada readers on the doors,” Mike said. The seamless access control integration with the existing camera system made security management more streamlined and efficient, allowing the client to control who entered their facility with the same ease they now accessed their surveillance footage.

Key Considerations for Physical Security Upgrades

Mike stresses the importance of thoroughly assessing your infrastructure when considering a physical security upgrade. “Wiring can be a factor depending on the age of the system. Older analog systems need new wiring, but IP systems not so much. The network also has to be sound, especially since we’re delivering power over Ethernet (POE). The client had level three managed switches, which provided enough power to all the cameras, but when cameras start to pan, tilt, zoom, or have other functionalities, delivering adequate power is key.”

Mike’s advice? “Try it out. Sometimes you don’t know how bad you have it until you see what else is available. A lot of companies deal with pain and just figure it’s part of the job. But there’s a lot of value in being able to manage a system like this. It’s easier to implement than you’d think, and it makes managing security so much simpler, especially for companies with multiple remote sites.”

Verkada Support: A Key Advantage

Verkada’s support system also played a critical role in the client’s satisfaction with the new setup. “They have a chat feature, and when you call in, hold times are usually under a minute or two. I can probably count on one hand how many times I’ve had to sit on hold,” Cameron shared. This reliable, quick support was another big improvement over the previous system, which often left the client waiting for assistance.

Conclusion

For this manufacturing client, the transition to Verkada’s cloud-based security system, implemented by VLCM, provided immediate benefits in terms of both functionality and ease of use. With the ability to manage surveillance and access control from anywhere, security has become simpler and more reliable. This success has even opened the door for potential upgrades at other facilities, as the client continues to explore Verkada’s full suite of security solutions.

A great “thank you!” to Mike Rollins and Cameron Bagley for sharing this success story. To hear more from Mike Rollins, check out our Audiovisual Customer Success Story, VLCM Empowers Software Firm with Innovative Collaborative Conferencing Spaces. 

Additional Resources

• VLCM Physical Security Line Card
• How to Easily Scale Security Cameras and Access Control with Verkada
• Ease of Use, Maximum Security: How a Texas Church Convention Improved Security with Verkada Access Control and Cameras
• Iron Road Healthcare Simplifies Security Management with Verkada and VLCM

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