Q3-INTELLIGENCE SUCCESS STORY NUCOR

NUCOR STEEL SOUTH CAROLINA

THE CUSTOMER

Nucor Steel South Carolina is South Carolina, . a premier producer of angles, Since beginning of operations in channels, flats, rounds, rebar and 1969 as Nucor Corporation's first hexagons. Nucor also produces bar mill, Nucor Steel Darlington rod, bar, and hex in coil. The has grown to become the largest facility is located in Darlington, bar producer in the Southeast.

Nucor Steel South Carolina’s tools to support the mill output. facility consists of two high The Q3-Intelligence System THE CHALLENGE efficient bar mills that accomplished the need to produce special bar quality, merge heterogeneous sources merchant bar quality, and into a single data warehouse, reinforcing bar products with over transforming data streams into 600 distinct steel grades. useful information to optimize Being the quality a priority for the whole process. the rolled products, it became essential to have a centralized repository able to correlate the process information to the finished products in order to use analytical

3 DANIELI AUTOMATION

The Business Intelligence (BI) Server to support IT-developer- analysis templates THE SOLUTION vertical solution for the metals centric data management, and the exhaustive KPI library. industries developed by Danieli reporting and administration Q3-Intelligence extends Automation is a real time data requirements, while business- information delivery systems monitoring system and data user data analysis needs are towards being complete analysis platform. Q3-Intelligence delivered by the web dashboards decision platforms by combining is based on the Microsoft BI and and through Microsoft Excel via operational data streams with Analytics platform using SQL the custom Q3-Intelligence data advanced analytical tools.

Q3-Intelligence Business Intelligence

Dashboards & KPIs for PC and mobile devices Business Analytics for PC and mobile devices

Q3-Intelligence Data Warehouse Q3-Intelligence Semantic Model Metals Industry Tailor-made Self-Service Business Intelligence Embedded Key Performance Indicator Library Advanced Analytics Data Governance Secured Access

Q3 Data Extraction Procedures Data Centralization & Normalization Data Validation & Cleansing

Data Sources

Danieli Level 2 Laboratory High Frequency Process Variables Process Control Systems File System ROLLING MILL #1 ROLLING MILL #2 PCS PCS LABORATORY ROLLING MILL #1 ROLLING MILL #2

ROLLING MILL #1 & ROLLING MILL #2 PLANT AUTOMATION AND LABORATORY SYSTEMS NUCOR STEEL SOUTH CAROLINA (NSSC)

Q3-Intelligence set up and rules; the Roll Shop Module, that Nucor personnel to properly “The role based access methodology provides regular and timely roll configure the system. Due to to the data makes it simple Danieli Automation’s Level 2 and setup shop management the needs to centralize and for our team to use System commissioned modules information to operators. correlate Danieli’s Level 2 system Q3-Intelligence” comprises the Production Through automated tasks, all data with a third-party system Module, that manages the flow this data is centralized into the (laboratory data), an interface of data from the time billets Q3-Intelligence System data to exchange data was studied are charged into the reheat warehouse, that thanks to the and design on site to import Ben Souther, Rolling Mill furnace up to the end of the mill predefined and built-in interfaces the laboratory test results into Supervisor, Nucor lines; the Downtime Module, towards Danieli Automation’s the Q3-Intelligence centralized that tracks and categorizes Level 2 System, makes it a plug repository. scheduled and unscheduled & play application. Finally, the wide usage of the downtimes; the Quality Control The software commissioning was Microsoft SharePoint framework System Module, that aims to carried out throughout different led to the integration of the automatically identify the quality steps by means of several visits Q3-Intelligence modules into level of the rolled products on on site, in which the integration Nucor’s SharePoint portal, the basis of measurements of new modules and system leveraging the usage of the collected during the process tuning were performed gradually centralized data model thanks to and the application of a set of according to Nucor’s standards. its native compatibility with such pre-defined quality evaluation Each phase involved specific environment.

4 NUCOR STEEL SOUTH CAROLINA

Custom-tailored management Performance Indicators (KPIs) through the SharePoint portal by of data and then tracks down the means of several features such “The power of Q3- Gigabytes of information that production to single day/shift as Excel Web Services. Intelligence data analysis were previously stored across details or to production order system has made it a true several independent relational details, with ready access to Role-based access to data tool for us to use; not just databases are now inserted specific custom reports. The need for high level The another piece of software” into a custom-tailored data need for high level restrictions warehouse and analysis data Boosted data analysis to certain information is easily models. One-click access capabilities fulfilled using the to process data which had Analytical data structures and Q3-Intelligence integrated Ben Souther, Rolling Mill previously taken hours to track data models are constantly security functionalities, based Supervisor, Nucor down is now instantly available. updated with production on Active Directory. For both data, overcoming the need systems, the web dashboards Enhanced real-time production to easily and immediately and Excel analysis workbooks, it monitoring correlate any information, from is possible to rapidly set up roles Real-time data visualization timings to quality and process with customizable privileges, tools, showing graphical variables, throughout different thus preventing unauthorized snapshots and historical trends perspectives, aiding decision- accesses. Finally, any configured enabling end users to instantly making activities. This data security role is automatically be informed about the status structure architecture permits to inherited by SharePoint, making of both production lines. The historize the information, giving it simple to handle security web dashboards are fully the ability to compare production accesses. configurable, allowing to monitor trends and performances over specific production KPI’s and the time as well to correlate the BI power to staff in order to metrics according to single product’s quality to any process improve the business user’s needs. Visualization is of its process variables. All this Nucor Steel Darlington enhanced with the adoption of information can be accessed recognizes the additional value a top down dashboard design from the company’s intranet Q3-Intelligence brings to its that starts with the automatic through the ready-to-use Excel users. This is guaranteed thanks evaluation of individual Key dynamic analysis templates or to the use of a wide-ranging data analysis platform comprising multiple data analysis tools for different needs, which permits the correct analyses of the data that is gathered. It is a powerful tool for production teams, quality assurers, process engineers and other business process key users, and allows such to focus on the monitoring and analysis of process data, thus reducing the time needed to reveal the underlying reasons for production anomalies.

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Q3-Intelligence leveraged the > Centralized production data > Self-service BI that THE BENEFITS value of the existing process generated from multiple process permits users to query data data to achieve a real-time control systems independently without needing and unified view of actual and > Ordinary front-end tools (Web extensive IT skills historical plant performances. All Browser and Excel) shortening > Extranet access to information users from both mills have now learning curves thanks to the native integration the possibility to readily browse > Improve ease of access to with Microsoft SharePoint Long production information thanks data in terms of front-end time storage of all production to a centralized repository of analyses, system performance data in centralized data integrated data from multiple and maintenance by internal IT warehouse for advanced data sources. Q3-Intelligence personnel analysis includes fully customizable > Significantly decreased time to > Archiving of historical data advanced statistical tools which access internal data streams, via that is purged from the source offer short learning curves for a unified methodology systems first time users. > Real time monitoring of plant > Optimize complex data Q3-Intelligence has transformed production data together with the accesses while avoiding any reporting at Nucor by reducing integration of existing reporting impact on the operational source the manual data access and by tools systems delivering a centralized real-time > Customization of advanced > A single data model for all data view of the production. dynamic data analyses regardless its source

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