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AUTOMOTIVE MANUFACTURING CUSTOMER STORY

How Sitemetric gave an electric vehicle manufacturing campus one live headcount for construction and plant operations

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Project summary

1,482,381
On-site hours
479
Active days
241
Total companies
3,100+
Construction workers
2,200+
Equipment and operations workers
204,804
Worker-days
428
Daily average workers
THE CHALLENGE

An EV plant expansion built alongside live vehicle production.

A national general contractor took on a plant expansion at an electric vehicle manufacturing campus, adding new production buildings beside a plant that kept producing vehicles. Construction crews worked alongside the owner's production equipment and automation installers, and both the owner and the contractor needed to know how many people were on site at any moment. Over the project, more than 3,100 construction workers and 2,200 equipment and operations workers came through the campus. Over 479 active days, the site averaged 428 workers a day, peaked above 1,500, and saw as many as 99 companies on site at once. Work continued through 135 weekend days.

The contractor needed to:

  • See one live headcount across construction and operations
  • Control access across construction and operations areas of an active campus
  • Move large crowds through multiple gates quickly at shift changes
  • Know which companies and trades were working in each building
  • Report on-site hours across 240+ companies
THE SOLUTION

Integrated Construction Intelligence

The contractor chose Sitemetric as one partner for access control and workforce visibility across the campus. Every person entering the campus was badged in, including equipment installers and owner staff, not only construction workers. Turnstiles and badge readers at the main gates, building entrances, and the operations side of the campus verified each worker. Sensors in 43 zones showed where crews were across buildings, parking areas, and field offices.

  • Turnstiles at key entrances across the campus, including the operations side
  • Real-time construction and operations headcounts, plus a combined campus total in one view
  • Automated daily manpower and on-site hours reports across 240+ companies
Sitemetric dashboard showing a live headcount on an EV plant expansion

“On an active EV plant, construction crews, equipment installers and the owner's operations staff are all on the same campus. With Sitemetric, the GC and the owner could see all of them in one live headcount. That gave the teams peace of mind that if there was an emergency, or it was the end of the day and everyone needed to be off site, they'd know who was still out there.”

Regional Leader, Field Tech

Sitemetric

THE RESULT

Nearly 1.5 million on-site hours in one connected record.

The team gained one connected record of nearly 1.5 million on-site hours across construction and operations on an active campus.

ONE HEADCOUNT FOR THE WHOLE CAMPUS

Construction and operations totals rolled up into a single campus count, so no one had to switch platforms to see who was on site.

BUILT FOR PEAK DAYS

On 156 days, 500+ workers were on site, with a peak above 1,500. Each entry was verified at the gate as crews arrived.

BUILDING-LEVEL VISIBILITY

Nearly 800,000 zone entries across 43 zones showed which companies and trades were in each building, supporting daily planning and subcontractor accountability.

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