Volkswagen Sachsen automates truck entrance

Every day, around 1,100 trucks pass through the South Gate of Volkswagen Sachsen GmbH’s vehicle plant in Zwickau. To make the demanding just-in-time logistics more efficient and relieve the burden on security personnel, the automotive manufacturer relies on a fully automated access control system from Interflex. The result: optimized processes, reduced wait times, and significantly increased occupational safety.

The entrance at the South Gate is the logistical lifeline of the VW site in Zwickau, where six fully electric models from Volkswagen, AUDI, and CUPRA are produced. Previously, processing 40-ton trucks every minute meant pure stress for the security staff: checking papers, scanning ID cards, and verifying license plates – all manually on a narrow traffic island in the middle of heavy traffic. To eliminate this bottleneck and prevent costs from skyrocketing due to staffing increases, corporate security looked for a digital solution.

Smart Two-Factor Authentication

Together with Interflex, the long-standing solution partner for access control at the site, the entrance was transformed into a traffic light- and barrier-controlled separation system. The heart of the new solution is a clever two-factor authentication: Interflex’s video-based license plate recognition is combined with driver identification using long-range ID cards (UHF readers from partner deister electronic).

The IF-6040 management and system platform acts as the central data hub where all processes converge. Freight forwarders can register their drivers and vehicles in advance via a portal. Upon entry, the system checks the recognized license plates and ID card data against the stored authorizations in real time and opens the barrier automatically.

Noticeable Relief and a 96 Percent Recognition Rate

The daily routine for the security guards has changed fundamentally. Instead of manually operating barriers between moving trucks, the focus is now on monitoring. Using the customized software reception dialog of the IF-6040, employees have a constant overview of all vehicle and personnel movements.

“The monitoring system was very well received by the security staff because all the information is now available at a glance. The relief is noticeable for everyone,” explains Marcus Kaestner, Head of Site Security at VW Sachsen. Occupational safety has also noticeably increased, as the trucks now drive in a controlled manner in the outer lanes, and the staff is no longer constantly surrounded by vehicles.

With a recognition rate of around 96 percent from the long-range cameras and the ability to operate the system offline in the event of disruptions, the smooth flow of just-in-time deliveries is guaranteed.

Would you like to learn more about this exciting project? You can download the complete reference report for Volkswagen Sachsen GmbH as a PDF here.