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News > Case studies
Manufacturing : Henkel expansion prompts digital upgrade
Henkel is the world leader in adhesives manufacture. Those unfamiliar with the Henkel name are likely to know many of its products such as Solvite wallpaper adhesive, Loctite Super Glue, UniBond sealants, Sellotape and Pritt. Its facility in Winsford, Cheshire is the manufacturing base for many of the most popular brands and the site has recently been expanded to include a major new distribution warehouse.
"We’d had an eight camera system for about 10 years, but technology had moved on considerably over that period," says Henkel Safety, Health, Environment & Quality Manager David Harrison. He was finding that the costs of maintenance were rising, cameras were failing, there were problems with cabling and the old infra-red bulbs were constantly blowing. The system was "out of the dark ages" recalls Senior Security Guard Mark Wood. Video tapes were hard to manage and the cameras "kept missing things".
Worthwhile investment
Henkel has now replaced this with a 14 camera installation linked to two monitors and a digital recorder. Henkel depends on CCTV primarily as a management tool, particularly with respect to traffic control. The Winsford plant is exceptionally busy, with a constant stream of vehicles entering and moving round the15 acre site. About 100 lorries a day, almost 500 staff and 200 visitors contribute to the lines of traffic passing the gatehouse.
The gatehouse team uses the system as "another pair of eyes", explains David Harrison. Every entry and exit is recorded, as is the progress of vehicles on site. Previously, there might have been half a dozen lorries queuing to get into a bay – now there will be only one. The CCTV system is used to co-ordinate movement and ensure that lorries are instructed to wait out of the way. If, despite best endeavours, a collision does occur then the cameras help identify why it happened.
Building the team
"We wanted to find a supplier who would provide a good service, quality products and be able to demonstrate that they could meet deadlines," says David Harrison. Liverpool-based OSS Security fitted the bill on all counts.
"OSS is a family run business, is based close to us and has been operating for a number of years," he says. "I was very impressed by the knowledge within the organisation."
Four colour mono Vista PowerDomes (VPD-3WP-P-C) are sited externally while the interior of the new warehouse is fitted with wall mounted colour mono Vista PowerDomes (VPD-1DP-P-C).
Eight static Vista cameras (NCD735Cke) with integral lenses keep watch over hotspots such as loading bays where constant coverage is essential.
The 14 camera system feeds to a Dedicated Micros Digital Sprite 2A digital video recorder with a 320GB hard disc (DS2A DX16C-320GB). Two Vista 17" colour monitors (PVD1700DG) provide gatehouse staff with a clear view of the entire operation.
The upper monitor cycles through all 14 cameras unless overridden, while the bottom one is normally set to display an index shot of each. Larger views in panes of four can be used to make observation easier at night. For the night shift, all cameras are put into a static mode, trained on key positions which can be overridden if necessary.
Installation was very smooth, says David Harrison, as people in OSS "went the extra mile", and worked closely with Henkel’s engineering and production teams to ensure the work fitted in with other projects.
Operational benefits
"It's a great system" says Mark Wood. Life in the gatehouse is now a lot easier, thanks to features such as the near-instant access to archive footage. "It once took us two days to find the correct tape for an incident involving a lorry – this would pick it up in 30 seconds."
Recordings are generally kept for a month. A clip of five minutes is generally all that is needed to record an incident, and this clip can be saved using the CD writer (UKSCX/SW EXT CD RWS) in the control room.
The investment has earned its keep on many occasions, for instance by giving visible proof of deliveries. On one occasion, a customer was questioning the number of pallets received. It took just moments to prove to the customer’s satisfaction that the full complement had indeed left Henkel's premises.
[Equipment list]
2 x VPD-1DP-P-C wall mounted colour mono Vista PowerDomes
4 x VPD-3WP-P-C outside colour mono Vista PowerDomes
8 x NCD735CKe Vista black and white static cameras
2 x PVD1700DG 17" colour monitors
1 x DS2A DX16C-320GB Dedicated Micros 16 way 320 GB digital recorder
1 x DM/KBS3 Dedicated Micros keyboard joystick
1 x UKSCX/SW EXT CD RWS CD writer
[Installer profile]
OSS Security is a family-run business that provides a one stop shop for CCTV systems, intruder alarms and access control. The company has traditionally operated within 100 miles or so of its Liverpool base but is increasingly working further afield. Projects have recently been carried out in London and South Wales and Operations Director Julian Davies says that the intention is to continue to roll out the company's business nationwide.
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