The requirement
The engineering and manufacturing factory operates two shifts for approximately 16 hours each day across two connected factory and warehouse buildings. Six cameras had no image or intermittent video, two further feeds were unstable, recording was inconsistent on several channels and remote viewing was unavailable.
Site challenge
The faults did not have one common cause. Testing identified damaged outdoor network cable, failed RJ45 terminations, two faulty PoE/power components, moisture ingress at an outdoor junction and incorrect network and remote-viewing configuration. Work also had to be scheduled around live factory operations.
System and equipment
The site had a 24-camera Hikvision system using more than one recording path. A Hikvision DS-7716NI-I4/16P 16-channel PoE NVR formed part of that wider recording setup; it did not handle all 24 cameras. The repair approach tested cameras, cable routes, terminations, PoE/power, recorder settings, storage and network configuration before deciding what required replacement.
Work completed
- Replaced approximately 70 metres of damaged Cat6 cable and failed RJ45 connectors
- Rectified the moisture-affected outdoor junction and repaired camera connections
- Replaced two faulty PoE/power components
- Replaced two cameras that had suffered hardware failure
- Corrected NVR, network and remote-viewing settings
- Retained the existing 4 TB hard drive after health, recording and playback tests
- Completed work around production activity, attending active areas during lower-activity periods
Project outcome
Eight previously unreliable or offline channels were restored, including two positions where failed cameras were replaced. Recording was normalised, remote viewing was restored and the existing CCTV system remained in service without wholesale replacement. The 4 TB storage provided approximately 14–18 days of practical recording under the final configuration. A quarterly preventive-maintenance AMC was then agreed.
Ongoing maintenance
Quarterly AMC visits cover camera cleaning and alignment, image-quality checks, recorder and hard-drive health, recording and playback, remote access, network and PoE performance, cable and connector condition, plus firmware and configuration review.
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