IATF customer audit closed in 90 minutes. Zero findings.
Tier-1 auto component plant, Chakan · Pune-Chakan-Aurangabad
A 1,200-worker Tier-1 component supplier in Chakan, serving two major OEMs, used to spend three nights of HR effort and two days of Security review before every IATF customer surveillance audit. Post-Zentry Sitewide, the same audit closes in 90 minutes from a live console. Zero findings on the access section.
| ZONE A | Production floor | 100% |
| ZONE B | Paint shop | 100% |
| ZONE C | Tool room | 100% |
| STAFF | Suprema linked | 380 / 380 |
| CONTRACT | Agency licences | 47 / 47 |
| ANPR | Inbound matched | 184 / 184 |
| FORM XVI | Generated for period | Ready |
What the plant was facing.
The plant had three separate vendor stacks at the gate: a visitor book in the security cabin, a Suprema biometric for staff attendance, and an Excel-based contractor muster maintained by the HR team. None of the three reconciled to each other. Every quarterly IATF customer audit and every Labour Officer visit required the HR team to spend three nights rewriting Forms XIII through XXIII into the prescribed format from the contractor agency bills and the biometric exports.
The breaking point was an IATF customer audit where the customer's auditor asked for per-zone access logs for the previous 90 days. The existing system could not produce them. The audit closed with a major finding. The customer flagged the plant as a supply-risk for the upcoming model year. The Plant Head asked Procurement to find a platform that could pass the next customer audit without a three-week prep cycle.
How Zentry was deployed.
Zentry Sitewide replaced the three vendor stacks with one platform. The existing Suprema biometric and Honeywell ANPR hardware stayed in place. Gate Access view replaced the legacy access control software. Gate Muster view replaced the Excel contractor muster. Pass replaced the visitor book. Drive replaced the security cabin's paper vehicle register.
The Zentry modules in this deployment.
What Zentry Sitewide produced for the plant:
Per-zone access logs for every staff and contractor entry, ready for IATF customer audits. 90-day, 180-day or annual export in 12 seconds.
Forms XIII through XXIII auto-generated for every Labour Officer visit. Per-agency, per-period, in the Central Rules format.
DPDPA-compliant visitor management. Customer auditors and OEM quality engineers checked in via kiosk, NDA captured, host alerted in 12 seconds.
Every inbound truck plate matched to its e-Way Bill at the gate. Inbound logistics traceability for the customer's supply chain audit.
The metrics that moved.
What happened at the next audit.
The first IATF customer surveillance audit post-Zentry closed in 90 minutes with zero findings on the access control and contractor management sections. The next Labour Officer CLRA inspection closed in 35 minutes. The customer removed the supply-risk flag at the next quality review.
"We used to dread customer audits. Three nights of HR rewriting Forms, two days of Security pulling logs from three different systems. The first audit after Zentry went live, the customer's auditor watched us export the access pack from one console in 12 seconds. The audit closed in 90 minutes. That was the moment we knew the bundle had paid for itself."All case studies →
Request a reference call.
We can connect you with a Plant Head or EHS Head at a similar plant under NDA. Hear the story from the customer, not the salesperson.
Common questions on this deployment.
Is this a real customer or a composite?
Composite story drawn from real Zentry deployments at Tier-1 component suppliers in the Pune-Chakan-Aurangabad auto cluster. Specific industry, geography and metrics are representative of the deployment pattern. Named customer references are available under NDA during qualification.
Did the plant keep its existing Suprema biometric hardware?
Yes. Gate works with Suprema, ZKTeco, Matrix, ESSL, Honeywell and Hikvision hardware out of the box. The legacy access control software was replaced by Gate Access view. The biometric hardware investment was preserved.
How long did the deployment take?
6 weeks from contract signature to go-live. Cloud tier was chosen, which is the fastest deployment path. Hybrid Edge or On-Premise tiers add 2 to 4 weeks.
What was the TCO position?
AMC spend dropped 38% versus the sum of the three vendor stacks that Sitewide replaced. The bundle pricing was 30 to 40% below the sum-of-parts, which is consistent with the Sitewide bundle position.
Did the plant face any change-management issues with the Security team?
Some. The Security team was used to the legacy access control UI. Two-day training was conducted during go-live. Within three weeks the new console was the preferred view. By the first audit, the team was driving the demonstration confidently.
Does the plant export the audit pack manually or is it automated?
Both. The console produces a live audit-ready dashboard during the inspection itself. For pre-audit submissions to the customer, the audit pack is a one-click export in PDF or Excel.
Has the plant upgraded from Sitewide to Sitewide+ since?
The plant is evaluating Induct (mandatory induction at entry) for the safety upgrade ahead of the next IS 14489 OSH audit. The upgrade is configuration-only, no re-deployment required.
Can other Tier-1 auto plants reference this deployment?
Yes. Named references under NDA are available during the qualification process. The reference plant typically hosts a 30-minute call with the prospect's Plant Head and Security Head.
One event. Six audit narratives.
Every gate read, every kiosk submission, every certificate validation lands in a single tamper-evident, signed log. From that one event, six modules produce six distinct evidence trails, for six different audits, six different inspectors and six different heads inside the plant.