AUTOMATED WAREHOUSE – TRI-STATE
The client was a major distributor of a highly sought after product ranging in price from under one hundred dollars to several thousand dollars with product items arriving from throughout the world. Items were typically packaged in boxes of 12 – 24 units, but a significant percentage of customers might also order by individual item which were then collected and placed in suitable boxes.
To make things more interesting, the client was merging several existing warehouses into a new warehouse under construction in a different area of the State. There was some degree of automation at one of the existing warehouses, but not on a level that was planned at the new central warehouse.
Wivenhoe Group were tasked with a three-part consulting assignment based on the following objectives:
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- Acquire a reasonable understanding of the client’s warehouse operations at the existing main warehouse location.
- Acquire a reasonable understanding based on discussions with client warehouse management, and detailed analysis of the new facility drawings as to how current operations may change at the new warehouse facility.
- Assess existing security equipment at the main current location.
- Carry out a Threat Assessment for the new facility.
- Assess new central warehouse in conjunction with drawings and planned operation of same.
- Based on criteria above, put together outline security plan for discussion with client warehouse management to arrive at acceptable security plan. Include order of magnitude costs.
- Given agreement of (F) above, develop a “turnkey” integrated security solution to secure and protect the new warehouse facility.
Solution to include integrated security system involving Electronic Access Control and Point Monitoring, IP Camera Surveillance, Advanced Monitoring and Video Analytics, Perimeter Control with Automated Gate Systems, and additional security recommendations such as Security Awareness, Situational Awareness, Active Shooter Training, and other security elements.
- Meet and discuss all elements of (G) above and obtain approval of Security Solution from client warehouse management.
- Develop detailed specifications and security drawings that will form the core of an RFP Bid Package.
- Complete RFP Bid Package and upon approval from client warehouse management, distribute to an agreed list of qualified security integrators.
- On behalf of client warehouse management, conduct pre-bid site meeting and thereafter, answer all bidder questions pertaining to system design, RFP requirements, etc.
- Assist client warehouse management with an evaluation of all received bids to arrive at an award of contract.
- Perform Contract Administration on behalf of client warehouse management to ensure successful installation and implementation of the integrated security system and associated security measures.
- Ensure full testing of integrated security system, and training of all selected staff on operation and programming of new security solution.
- Provide letter of acceptance of new integrated security system to client warehouse management.
Phase 1 of Consulting Assignment:
This phase would comprise (A-F) above being an understanding of client’s current warehouse operation at the existing location, the planned operation at the new central warehouse location, assessing all existing security systems and equipment at the current location, conducting a Threat Assessment of the new central warehouse site, culminating in the presentation of an Outline Security Plan for the new central warehouse facility.
Phase 2 of Consulting Assignment:
Phase 2 would comprise (G-L) above being development of a detailed “turnkey” integrated security solution, development of detailed specifications and drawings, provision of an RFP Bid Package, distribution to a qualified list of bidders (security integrators), conducting a pre-bid meeting on site on behalf of the client, evaluate all received bids on behalf of client warehouse management and assist same in arriving at award of contract.
Phase 3 of Consulting Assignment:
The third phase would comprise (M-O) being be to provide Contract Administration, where acting on behalf of client warehouse management, the consultant team would ensure correct installation and implementation of the new integrated security system to include full acceptance testing, proper training of all selected client staff, and to then provide a letter of acceptance to client management.
Phase 1 Implementation:
Two senior consultants with Wivenhoe Group spent time at the existing main warehouse studying the warehouse operation which included a limited degree of automation, but also incorporated a specialized operation where various items were manually picked from inventory and then placed on a conveyor belt for packaging.
Pickers were assisted by a semi-automatic system that read orders and forwarded order items to the front of inventory.
A Threat Analysis was carried out assessing the current location and then projecting those threats and risk scenarios into the new location.
The analysis considered the following:
General Crime Levels
Specific Insider Theft
Specific Outsider Theft
Violence in the Workplace
Domestic Terrorism
“Active Shooter” Potential
Police/Guard Service Presence
Other Factors: Local Demographics
Nearby Targets of Influence
High Profile Product
Similar Events in Area
Security Legislation
Current Security Measures
Opportunity
The Threat Assessment surfaced the following major items:
- General Crime Level:
In assessing the general crime level, the consultant team spoke at length with the Local Police Department, utilized a CAP Risk report, and accessed various other local crime statistics data and other sources of knowledge.
Somewhat surprisingly, the CAP Index scores for the new warehouse location, based on a three (3) and six (6) mile radius were particularly high being 851 and 844 indicating that the overall risk of crime within each area is approximately 8.51 times and 8.44 times the National Average in the U.S.
- The new central warehouse site location was found to support far greater crime levels than that found at the existing warehouse locations.
- Given the area taken up by a major airport and adjacent water expanse, the crime rates were more significant, being more concentrated than normal.
- A further factor affecting general crime levels in the area was the very close proximity of a shopping mall and seaport which together with supporting hotels in that area would explain the elevated level of motor vehicle theft.
Based on the results of all aspects of the Threat Assessment, and analysis of all pertinent and available data, and studying current credible threat information related to the area, the threat level was identified as Medium to High Elevated Risk.
Phase 1 Security Recommendations:
Studying the existing warehouse operation and then studying the new Central Warehouse site and drawings, and applying many years of experience together with security industry standards and accepted practice, the consultant team were able to develop an appropriate Integrated Security System Outline and Plan.
Given what would be required to protect and secure the new Central Warehouse, the list of Headings included the following:
Existing Warehouse Recommendations:
- Access Control to Warehouse and Office Areas
- Warehouse Operations
- Existing Security Systems
- Protection of Key Staff & Data
- Process Protection
New Central Warehouse Recommendations:
- Location
- Perimeter Control
- Vehicle Access
- Physical Security (Guard Services)
- Integration of Security with Production
- Central Control
- Internal Security Practices
- Common Point Monitoring
- Remote Monitoring & Control
- Security Management Position
- Client Corporate Electronic Access Control
Phase 2 Implementation
Having obtained the client’s approval, the consultant team commenced a detailed system design with drawings for a new Integrated Security System that would meet all security requirements for the new Central Warehouse.
The primary components of the integrated security system were as follows:
VMS (Video Management System) Core Hub of the System.
Security Management System Secondary Hub in Conjunction with the VMS System.
IP Camera Surveillance Forms Basis of Total Property Monitoring & Intrusion Detection Together with Electronic Access Control & Point Monitoring.
Perimeter Control An Essential Element in controlling access to the central warehouse complex by unauthorized individuals.
Vehicle Control Important Part of System.
Guard Services Crucial Component.
Security Intercom Necessary component for both staff entry point and main entry point, particularly at night.
Visitor Management Important Part of System.
Security Communications A Critical Component of the Network System allowing authorized users to send and receive messages such as alarm events with video, as well as monitor all cameras, alerts and alarm conditions on a remote basis.
This includes local law enforcement, Port Authority Police and DHS Patrols.
Integration with Other Systems An important capability of the new integrated security system providing interaction with other non-security systems such as Lighting, HVAC, and others.
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The integrated security system was required to address several specific challenges that included the following:
- Delivery Trucks Leaving the Central Warehouse
The client operates a fleet of delivery trucks that leave close together having been loaded overnight, but leaving via a single exit/entry point to the new central warehouse. The consulting team were able to design the exit/entry point in such a manner that two streams of trucks could leave simultaneously and still leave a lane available for vehicles entering the complex.
- Single Point of Main Entry/Exit
To accommodate staff vehicles, a secondary entry point was created away from the main entry/exit point that was entry only but with two lanes. These entry points were controlled via the security management system.
All vehicles, once in the complex were required to exit via the main exit/entry, also controlled via the security management system.
- Returns
There are daily returns of product which can be anytime during the day. Video surveillance of specific loading docks used for returns was critical to prevent miscounts of returned product.
- Guard Service
With a large, complex operation, it was highly important that the security guards be able to understand the full nature of the security system in terms of reacting to alarms and alerts from any location, controlling visitor vehicle access, controlling inbound and outbound truck access, and taking specific actions at peak periods.
Again, obtaining full approval of the client, the team then prepared a complete bid package comprising system specifications, detailed drawings (10), bid documents comprising bid form, instructions to bidders, and supplementary conditions.
It should be noted that the system specifications included a full schedule of equipment in addition to all equipment being shown on the drawings, as well as a camera matrix covering the more than 340 camera locations indicating camera type, location of camera and view required of the camera. (See Example Below)
Camera Reference Number
#138
Camera Type
Type 5
Location of Camera Per Drawing
Joist Mounted, Adjacent to Camera (140), in Mid-Warehouse Interior
Drawing Reference #
SEC 206
Camera Area Coverage
Looking Up North Along Main Aisle of Interior Warehouse & Facing Camera (152)
The bid package was then distributed to qualified security integrators and a Pre-Bid Meeting was then conducted by the consulting team in conjunction with client warehouse management. Thereafter, the team received bids on behalf of the client, evaluated same and assisted the client in arriving at award of contract.
Phase 3 Implementation
Contract Administration is a very important part of any security system design for a client where the consultant team acting on behalf of client warehouse management would ensure correct installation and implementation of the new integrated security system to include full acceptance testing, and proper training of all selected client staff.
One interesting aspect of the assignment was that concerning the network design and corresponding cabling. The client, for a variety of reasons elected to have the electrical and electronic IT contractor put together the network cabling and design with Wivenhoe Group consultants providing details of the network connections for all security devices and control boxes, etc.
As the total project progressed, there were issues with the layout of the network and incorrect positioning of network connections where Wivenhoe Group consultants were asked to assist the client in sorting out problems with the network, such that the integrated security system would operate correctly as intended. This was successfully accomplished in a very timely manner.
The consultant team attended most of the project meetings on-site which proved to be very conducive to catching several errors by different parties before they became major setbacks.
Testing and Inspection
The testing and inspection of the completed Integrated Security System is an essential part of the Contract Administration with Wivenhoe Group treating this section very seriously. The consulting team ensured that the entire system operated correctly and to specifications. Below is an extract from the Technical Specifications related to this assignment covering Testing and Inspection:
B. The system shall be tested for final acceptance in the presence of the Engineer and Owner Management, Installation Contractor’s representative and the security management system manufacturer’s representative. The Installation Contractor shall record and submit the test results to the Engineer and Owner Management.
C. Where appropriate, the following shall be tested during the final SAT:
1. Every video camera/lens focal length for proper operation, including low light level resolution, depth of field resolution, field-of-view, and video motion detection (as applicable).
2. Analytic programming of specified cameras.
3. Tracking capability of specified cameras.
4. Priority Alarm programming of specified cameras.
5. The video system digital video recording system, and headend work station-application management software.
6. The video system interface with the Property LAN.
7. Every proximity card reader and issued proximity cards.
8. Every NEDAP Vehicle Tag Reader and issued vehicle tags.
9. Every door contact, and overhead door contact.
10. All Gate Arm Operators and Gate Arm sensors.
11. All client server stations.
12. All Intercom Stations and Master Desk Stations.
13. Complete VMS Integration.
14. Every Duress Alarm (Panic Button).
15. Every Gate Arm Sensor.
Another important aspect of Contract Administration is to ensure that proper and adequate Training is provided to authorized client staff covering the entire Integrated Security System. Again, Wivenhoe Group consultants follow a stringent and successful training program. The extent of which can be seen from the extract below:
B. In addition to the above manuals, the Installation Contractor shall provide a trained manufacturer’s representative, or similarly qualified individual for four (4) periods of four (4) hours during normal business hours to instruct Fedway Associates warehouse and security management, security officers, and other designated personnel on the operation and maintenance of the integrated security system, as required and authorized. The full course shall be videotaped by the Installation Contractor and submitted to the Engineer and Owner Management. The following topics shall be included:
1. Overview of the total integrated systems operation.
2. Presentations of the user’s manuals and detailed instructions on how operate and execute all functions of the integrated security system.
3. Hands-on practice in the total system operation.
4. Maintenance procedures.
C. A typical training program for the Central Warehouse Integrated Security System would consist of the following array of topics:
- Introduction and Course Objectives
- Overview Description of System Components and Operations
a. VMS System Operation & Interaction with all Cameras, Camera Monitoring, Camera Video Recording, Camera Displays and Analytic Operation.
b. Security Management System, to include electronic access control, point monitoring, visitor management system, Photo ID Printer operation, NEDAP Vehicle Tag system, and Integration with VMS System. System and LAN and VLAN Interface Communications where applicable. Backup Power.
c. Security Intercom System to include all door station and master station operation and programming for same.
d. System and LAN/VLAN Interface Communications, where applicable.
e. Gate Arm Operators to include full operation.
f. Backup Power as applicable.
g. Surge and High Energy Protection
- Video System Operation
- System Setup and Operation
- Digital Video Recording Operations
- Digital Video Recording Capability
- Digital Video Recording Configurations
- Video Motion Detection
- Keyboard Control
- Keyboard Video Selection
- Control of camera function
- Alarm call-up operation
- Alarm acknowledgment
- Menu and Non-Menu Programming
2. Security Management System
a. – Access Control
card readers
vehicle tag readers
electronic locking devices
alarm sensors
b. – Visitor Management
c. – Controller and Distributed Processing
d. – Alarm Intrusion System
e. – Photo ID Card Printing System
3. Security Intercom System
4. Gate Arm Operators
5. Remote Monitoring of All Systems
6. Communications
- Types of Communications Systems
- Configurations
- Direct hardwire (Fiber Optic & Cat 6)
- Network Video Signals
- Network Back-Up, where applicable
- Trouble Shooting
- Prior to on-site start up of the system, training shall be provided for designated individuals in maintenance of the system. This training shall qualify personnel to do general system maintenance and shall include, as a minimum:
1. Preventative and routine maintenance.
2. Troubleshooting and diagnostics.
3. Hands-on hardware experience including at least replacement of all field serviceable components to the “board” level.
A minimum of two weeks prior to training, detailed operations and maintenance training course syllabuses shall be submitted to the Engineer and the Owner.
The Integrated Security System went into operation as planned with the system, particularly given the degree of camera data being collected to all ow the client to seriously consider AI (Artificial Intelligence) and machine learning, as the basis for an intelligent automated warehouse operation, with additional benefits to be gained in truck delivery planning, the loading and unloading of product and product returns.
Should you be considering a similar project with the intent of hiring professional security consultants to assist you, please contact us today!