Case study
Smart Manufacturing Campus
Manufacturing · Pune — Three-building campus with OT segmentation and unified security desk.
01 · Challenge
What the client needed to solve
A precision components manufacturer grew through acquisition, inheriting three plants with separate badge systems and flat networks bridging OT cells to corporate email.
Security incidents at loading bays were hard to investigate because video and access logs lived in different silos with mismatched timestamps.
02 · Approach
How Hello Trading structured the program
We ran joint workshops with plant security, IT and production leads to define zone policies per shift. Network design introduced OT DMZ segments with explicit allow rules; access templates mapped to HR roles with contractor expiry automation.
Cutover used a central security desk pilot before rolling credentials building by building.
03 · Solution
What was delivered
- Unified access platform across 860 doors with anti-passback
- OT network segmentation for 28 production cells
- Perimeter thermal cameras with analytics on loading bays
- Central monitoring tying access alarms to nearest camera
- Contractor kiosk with host approval and auto-expiry
- Monthly compliance reports for insurer audits
04 · Result
Measured outcomes
Investigation time for loading bay incidents fell from hours to minutes with correlated video and access data. Insurer walkthrough praised documented segmentation — premium review yielded favourable terms.
Tailgating alerts dropped 42% after reader placement adjustments and guard SOP updates, without adding headcount.
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