1. Case Overview
- Client Industry
- Manufacturing
- Location
- Gorgia, United States
- Factory Area
- Approximately 215,000 sq ft
2. Background
A major Japanese manufacturing company is strengthening its local production capabilities by constructing a new factory in Georgia, USA, in response to growing demand in the North American market.
To prepare for the start of operations, the company required a stable network infrastructure capable of supporting communications across a large facility—from office areas and production lines to warehouses and outdoor gates. At the same time, the new environment needed to align with the operational framework used at an existing factory on the same site so the current operations team could manage the system seamlessly. In addition, the network and cabling infrastructure had to be completed within a limited timeframe aligned with the factory construction schedule, requiring a high-quality deployment under tight timelines.
3. Challenges Before Implementation
When building the IT infrastructure for the new factory, the project needed to address three key challenges.
1. Detailed Scheduling and Project Management
Because the factory building was still under construction, installation work had to be carefully coordinated with the general contractor and multiple on-site vendors. Work schedules needed to be adjusted continuously to match frequently changing construction timelines. Access to certain areas—particularly the production floor—was restricted during specific phases of construction, limiting the available windows for installation work. This required highly efficient planning and execution.
In addition, this was a large-scale project involving multiple vendors. A centralized project management structure was required to oversee progress tracking, quality control, and risk management while coordinating communication with stakeholders in Japan.
2. Reliable Connectivity Across a Large Facility
Because the factory covered a large area, stable reliable connectivity was required across office areas, production floors, warehouses, and outdoor gates. The network also needed to be securely segmented for different purposes while maintaining a flexible design capable of supporting future expansion.
3. Security
From a cybersecurity perspective, firewall protection was required to secure network performance. In addition, the overall design needed to incorporate physical security systems such as surveillance cameras and access control. To meet the strict quality standards for installation required by Japanese HQ, careful adjustments were necessary to bridge differences in local work practices and construction standards.
4. Implementation Services
SYSCOM supported the launch of the new factory by building the network infrastructure from the ground up while addressing these challenges. The project included end-to-end services covering cabling installation, network design and implementation, security system deployment, operational design, and a maintenance framework, all centrally managed under a unified project structure.
1. Centralized Project Management
To align with the construction schedule, we worked closely with the general contractor, on-site vendors, and cabling contractors, flexibly adjusting work plans as the construction situation changed daily. We acted as the central hub to manage the entire communications among all involved parties, also handling progress reporting to the client’s stakeholders in Japan.
2. Reliable and Scalable Network Infrastructure
The network infrastructure was built primarily using Cisco products, including switches, wireless LAN, and authentication systems, providing high reliability and scalability to support connectivity throughout the factory. All equipment and network paths were configured with redundancy. Optical fiber was installed through two physically separate routes to ensure that communications continue uninterrupted even in the event of a system failure.
3. Integrated Security Architecture
For cybersecurity, next-generation firewalls from Palo Alto Networks were implemented to enable secure network segmentation and access control between production equipment and office systems. To strengthen physical security within the factory, Verkada security systems were deployed. These systems enable centralized management of product monitoring cameras in production areas, access control, and security gate monitoring. We also carefully coordinated with local contractors to ensure installation quality met the high standards expected by the client.
Client Feedback
Construction projects in the U.S. often experience schedule changes, and our factory build was no exception. For this project, our detailed production schedule had already been established, so delays in the building or IT infrastructure were not acceptable.
Although construction-related schedules changed frequently, the project was completed without delays thanks to SYSCOM who made adjustments such as compressing work timelines and changing the order of tasks.
Client Feedback
We learned about Verkada for the first time through SYSCOM’s recommendation. We found the system high-performing and intuitive to use mainly because it is cloud-based, information can be accessed from anywhere, and updates are reflected across all devices in real time. The Verkada cameras and access control systems became key elements in the design of our new factory.
Since building a new factory from scratch required many types of equipment and systems, having SYSCOM handle the majority of the work made our project management much simpler. Thanks to SYSCOM’s management, the local partner vendors also maintained a high level of work quality. The project schedule was met, and even the cable conduits were installed neatly and professionally.
5. Implementation Highlights
To ensure reliable deployment of the network and security systems within a construction environment, the project incorporated multiple strategies across preparation, on-site work, and project management.
1. Pre-Deployment Testing
To prevent issues during on-site deployment, several hundred pre-installation tests were conducted on the network equipment. These included not only standalone functionality tests but also failover tests and configuration validation in a simulated environment equivalent to the production environment. As a result, installation proceeded smoothly without unexpected behavior.
2. Risk-Reducing Design
The cabling design prioritized stability and redundancy. Optical fiber cables were installed along two physically separated routes to reduce the risk of service interruption due to cable damage or external events. For the camera system, installation locations, viewing angles, and monitored targets were carefully reviewed with the client in advance. Adjustments were made to achieve optimal coverage for applications such as product monitoring and access control. The system design also accounted for facility layout and lighting conditions to support reliable video capture.
3. Precision Installation
During installation and configuration, strict management procedures were implemented to clearly define responsibility in case of theft or incidents. Equipment positioning was adjusted with millimeter-level precision. Installations in elevated or specialized environments were also performed to ensure stable operations. Since multiple inspections by local authorities (County Inspections) were conducted during construction, equipment removal and site cleanup were carried out before and after inspections to avoid disrupting the construction schedule.
4. Structured Project Management
More than ten project documents including basic design documents and detailed design specifications were prepared to systematically organize all aspects of design, implementation, and operations. By centrally managing site coordination, progress tracking, risk management, and quality control, we successfully completed this large-scale multi-vendor project according to plan.
Through these efforts, complex infrastructure including network, camera, and security systems was deployed quickly while maintaining a high level of quality.
Client Feedback
For overall building security, eliminating blind spots in both camera coverage and the access control system was critical. The camera system consists of a total of 60 cameras. To align camera angles with our expectations, SYSCOM’s engineers visited the site multiple times and walked through the facility with the local vendor to fine-tune each camera’s positioning. Because the cameras were installed after their thorough on-site verification, we have had no concerns about camera positioning after handover.
For access control as well, SYSCOM engineers walked throughout the factory and became very familiar with the building layout, which allowed them to determine the best locations for the security gates. They also configured the system so that security permissions can be quickly updated for each employee, supporting a highly secure environment.
6. Results
The most significant outcome was the successful delivery of the network environment in full alignment with the construction schedule. This enabled production equipment installation to begin as planned and ensured that key milestones for the factory launch were achieved.
Wireless LAN access points were strategically deployed across the entire facility including offices, production areas, warehouses, and outdoor gates to provide stable connectivity throughout the site. Following installation, a full-site wireless survey was conducted and heatmaps were generated to perform final optimization, ensuring the highest possible wireless performance.
Operationally, the system was designed to match the framework used in the client’s existing factory, allowing the operations team to manage the environment without disruption. In addition, 24/7 monitoring and pre-positioned spare equipment were implemented to minimize response time in the event of system failures and significantly reduce operational workload.
The infrastructure was also designed with scalability in mind, including bandwidth capacity of up to 40G and sufficient optical fiber cores for future expansion. This enables the factory to accommodate increasing numbers of IoT and AI devices in the future.
Through these efforts, the new factory now operates on a stable, highly available, and scalable IT infrastructure capable of supporting long-term production activities.
Client Feedback
Our new factory began operations last June, and we have not experienced any system failures so far. The camera system has become one of the most frequently used tools in our daily operations. When abnormalities occur, the camera footage serves as the most reliable source of evidence.
The network has been operating without issues. Even during equipment installation—when approximately 50 vendor personnel were on-site using multiple devices—no communication disruptions occurred. The access control system is also highly flexible, enabling security permissions to be quickly assigned on an individual employee basis.
7. Project Members
Project Manager: Yasuko Koda
Engineers: Yuki Hisata, Ikuma Tabata
Account Executive: Hikaru Kayamori
Engineer's Comment
During the project, key system parameters were defined based on the basic and detailed design documents that form the foundation of the overall system. We designed the system to balance simplicity and scalability. While these goals can sometimes conflict, planning for future expansion from the beginning allows the system to support the client’s needs over the long term.
The network was designed with full redundancy to ensure network communications never stop. By separating areas requiring high bandwidth from those that do not, we were also able to optimize costs. This project included physical security design, bandwidth planning, and video data backup. We believe we achieved a system that balances standardization with ease of use for the client.
Yuki Hisata Solutions Architect/Engineer
8. Why SYSCOM Was Selected
Client Feedback
We selected SYSCOM through an RFP process comparing three vendors. SYSCOM’s proposal stood out due to the quality of its presentation, proven track record, comprehensive support structure, and reliable local partner network. Their ability to communicate in both Japanese and English was also a major advantage.
We were pleased to see that they had a strong understanding of Japanese business practices and strict adherence to schedule management, which played an important role in the project’s success. Led by Project Manager Ms. Koda, the team provided consistent, hands-on support throughout the project. Despite the complexity involving multiple systems, the project was completed successfully and on schedule.
We would definitely recommend SYSCOM for other projects as well.
9. Conclusion
SYSCOM is a comprehensive IT solutions provider that delivers optimal digital solutions to solve clients’ business challenges. From consulting and solution design to implementation and operations, SYSCOM provides end-to-end support across a wide range of technologies, including IT infrastructure, ERP and CRM implementation, data analytics, and application development.
For large-scale infrastructure projects such as this one, SYSCOM combines strong project management with deep technical expertise to deliver reliable results—even in complex environments involving multiple stakeholders.
If you have any IT needs or are interested in digital transformation, please feel free to contact us.