Case Studies

Automotive Plant Dharuhera

CP PLUS ensures Security and Smooth Manufacturing Process at BWI Plant

Factories and other manufacturing facilities can benefit from the security provided by video surveillance. Theft of raw materials like lumber, copper and steel is at an all-time high, and thieves are targeting factories and other storage facilities with higher frequencies. Many factories also rely on highly guarded trade secrets to remain competitive. A comprehensive system of security cameras can help protect building, employees, and materials, as well as help management remain competitive in a growing market.


BWI Automotive Technologies Pvt. Ltd, a manufacturing arm of China based BWI Group, has set up a new Auto Components project at Dharuhera in Rewari, Haryana. The plant manufactures Motor Vehicle Parts like front suspensions, trusts and shock absorbers. As one of the world's most technically advanced producers of high quality automobile products for small and premium segment, BWI management wanted to introduce CCTV surveillance to monitor production processes and to ensure Health and Safety policies were being followed. After analyzing analogue, hybrid and IP based CCTV systems, the management zeroed in on IP based system. They selected IP because it allowed them to easily integrate CCTV with their existing network while benefiting from cost-saving technologies such as PoE (Power over Ethernet), UPS (Uninterruptible Power Supplies), break-free recording with 100% fail proof redundancy and support for the latest megapixel camera resolution that is only available with IP cameras.


CP PLUS team faced the following challenges and requirements at the workplace, which observes all day human, material and machine movement and activities:

Privacy – Protect the privacy of employees by keeping cameras in public areas like manufacturing and administrative areas, and out of break rooms and restrooms.

Damage – Cameras that monitor manufacturing processes or heavy machinery can be damaged by falling parts or malfunctioning machinery.

Outages – Disruptions in power or electrical surges can damage system or interrupt recording, and may leave manufacturing plant vulnerable to theft or other damages. While this type of damage is rare, it's important to have a backup form of security to protect employees and building should this type of disruption occur.

"The risk generally varies throughout a manufacturing plant, with areas where high-value raw materials, mostly processed one, are being handled posing the highest risk. Therefore, the level of security in various areas varies depending on the risk profile. Companies might also rely on surveillance equipment to provide them with feedback on safe work practice" Yogesh Dutta, COO, Aditya Infotech Ltd., added.


CP PLUS team was equipped with a long experience to cater to any surveillance needs for any business vertical analyzed the client requirement and suggested a solution. The team decided to place cameras in entryways and exits of manufacturing areas and different workshops. HD cameras were installed in shipping/receiving areas to capture a good shot of each visitor who entered the plant.

CP PLUS team made sure cameras in open areas like work floors and storage areas are covered comprehensively by cameras in each corner, or by dome cameras mounted on the ceiling. The team covered more sensitive areas (e.g. dangerous machinery, valuable raw materials, etc) with vandal and weatherproof HD cameras.


CP-EAC-DY65ML2H1: 650 TVL High Resolution Camera, High Resolution IR Dome Camera with OSD - 20 mtr, 1/3" Sony Super HAD II CCD with AGC, AWB and BLC features.

CP-QAC-TC72L2-D: High Quality Image Sensor, 720 TVL High Resolution Camera, 3.6 mm Fixed Lens, IR Range of 20 mtr with 24 LEDs, IP66, AGC, AWB and BLC.


For the BWI, IP CCTV solution has more than proved its worth by saving costs, improving time and ensuring machinery is performing safely. The system is also highly flexible to deal with the fluctuating and often challenging environmental conditions across the site. Other benefits offered are:

Theft Prevention

Security cameras have discouraged theft as such incidents have reduced significantly. The modern surveillance camera helps administrative authorities to identify the thief and prosecute them.

Quality control

Video surveillance cameras helped the authorities to monitor and achieve quality control faster and more efficiently.

Remote monitoring

NVR (Network Video Recorder) broadcasts the security footage at the plant over the internet to the authorized staff; making it easy to check up on any of your cameras at any time.

Workplace safety

Surveillance cameras placed near dangerous machinery are monitoring automated processes safely and are protecting employees from harm.

Easy to install

A surveillance system with IP (Internet Protocol) cameras is easy to install and maintain. Unlike their analog counterparts, which require power tools and technicians, all you need to do is mount the cameras and connect them to your video recorder or a computer.

System Integrator: Z plus Surveillance Security Pvt.Ltd.