Implementing an OEE Report in Power BI for Port Operations

QCAi Enables Real-time access to on-premises SCADA data

Case Study QCAi Implementing an Operating Equipment Efficiency (OEE) Report in Power BI for Port Operations

– Case Description | Company Challenge

The customer requested that QCA Systems Implement an Operating Equipment Efficiency (OEE) report in Power BI, where data must be curated and the data was based on an existing data collection method, based on SCADA measurements from a data historian. The equipment for this report was conveyer system metrics at a material handling port facility.

Overcoming these challenges requires collaboration between OT vendors, data engineers, and domain experts. This project involves understanding the specific requirements of the material handling port facility, implementing data integration and preparation processes, optimizing data modeling and storage, and designing intuitive visualizations and reports to facilitate effective OEE analysis and decision-making.

Real-time access to on premises SCADA data enabled - Case Study QCAi Implementing an Operating Equipment Efficiency (OEE) Report in Power BI Port Operations

– Here are some common challenges faced in this regard:

Integrating data from multiple sources and systems can be challenging. SCADA systems may generate large volumes of data from various sensors and equipment. Incorporating this data into Power BI requires data integration and transformation to ensure compatibility and consistency.

SCADA data may contain inconsistencies, missing values, or outliers that need to be addressed before generating meaningful insights. Data cleansing and preparation processes are crucial to ensure accurate calculations and analysis of OEE metrics.

SCADA data may be collected at different levels of granularity, such as minute-by-minute or hourly intervals. Aggregating the data to the desired level for OEE analysis and reporting can be challenging, especially when dealing with large datasets.

OEE involves complex calculations based on availability, performance, and quality metrics. Implementing these calculations accurately in Power BI requires understanding the specific formulas and equations involved in OEE calculations. Ensuring consistent and accurate calculations across different dimensions and time periods can be challenging.

SCADA data and historical data from the data historian may have different timestamps or data resolution. Ensuring proper time synchronization and alignment of data across different sources and systems is crucial for accurate OEE analysis and reporting.

Processing and analyzing large volumes of SCADA data within Power BI can impact performance and scalability. Optimizing data queries, using appropriate data modeling techniques, and implementing efficient data storage solutions are essential to maintain responsiveness and scalability in the OEE reporting solution.

In a dynamic environment like a material handling port facility, real-time data streaming from SCADA systems to Power BI can be challenging. Establishing reliable and efficient data pipelines to stream real-time data from the SCADA systems to Power BI while maintaining data integrity and minimizing latency is a critical challenge.

Designing effective visualizations and reports in Power BI to present OEE metrics and performance trends can be challenging. Identifying the key metrics to display, creating meaningful visualizations, and ensuring user-friendly dashboards that cater to different user roles and preferences require careful consideration and expertise.

Handling sensitive operational data from a material handling port facility necessitates robust data security measures. Implementing appropriate access controls, authentication mechanisms, and data encryption protocols within Power BI is crucial to protect the confidentiality and integrity of the data.

Company Overview

The client is a leading bulk handling facility located in North Vancouver, British Columbia, Canada. The company operates a state-of-the-art marine terminal that specializes in the handling, storage, and distribution of a wide range of bulk commodities.

With over 50 years of experience, our port client has established itself as a trusted partner for global producers, traders, and shippers. The facility is strategically positioned on the West Coast of Canada, providing convenient access to major shipping routes and enabling efficient transportation of goods to international markets.

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The terminal boasts extensive storage capacity and advanced handling equipment, allowing for the efficient and safe handling of bulk cargoes, including coal, potash, sulphur, and fertilizers. Equipped with modern facilities, the port offers a comprehensive range of services, including vessel loading and unloading, rail and truck logistics, quality control, and warehousing.

Safety and environmental stewardship are top priorities for the terminal. The company maintains rigorous safety protocols and adheres to strict environmental standards to ensure the well-being of its employees, the local community, and the surrounding ecosystem. By implementing advanced technologies and sustainable practices, the company strives to minimize its environmental impact and contribute to a more sustainable future.

The terminal is committed to providing exceptional customer service and tailored solutions to meet the unique needs of its clients. The company’s experienced team of professionals works closely with customers to understand their requirements and deliver efficient, cost-effective, and reliable bulk handling services. Whether it is assisting with logistics planning, optimizing cargo movements, or providing value-added services, the terminal aims to exceed customer expectations.

As a responsible corporate citizen, the terminal actively engages with the local community and supports various social initiatives. The company emphasizes community involvement, fosters positive relationships with stakeholders, and contributes to the economic development of the region.

In summary, the terminal is a leading bulk handling facility in North Vancouver, renowned for its expertise in handling and storing bulk commodities. With a commitment to safety, environmental sustainability, and customer satisfaction, the company continues to play a vital role in facilitating the efficient movement of goods and supporting global trade.

QCAi Work

To overcome the challenges of implementing an Operating Equipment Efficiency (OEE) report in Power BI.

Here’s how QCA Systems supports customers in this area:

QCA Systems implemented an efficient data integration process to transfer SCADA-collected measurements from the on-premises data historian to a cloud data warehouse. This involved setting up secure data pipelines, utilizing data integration tools and APIs, and ensuring proper data transformation to align with the cloud data warehouse structure.

QCA Systems designed and configured the cloud data warehouse to efficiently store and manage the on-premises SCADA data. We considered factors such as data partitioning, indexing, and performance optimization techniques to ensure fast data retrieval and cube processing.

QCA Systems implemented a real-time data streaming mechanism to transfer SCADA data from the on-premises data historian to the cloud database. This was achieved using technologies such like message queues and event-driven architectures to ensure near-real-time data availability for Power BI reporting.

QCA Systems designed and implemented an appropriate data cube structure in the cloud to support efficient and optimized querying for this OEE reporting. This involved creating dimensions, measures, and hierarchies that aligned with the OEE calculations and analysis requirements.

QCA Systems implemented robust security measures to protect the data during its transfer and storage in the cloud. We utilized encryption, secure connections, and access controls to ensure data confidentiality and integrity.

QCA Systems transformed the raw SCADA data into a suitable format for cube processing and analysis. This process involved data cleansing, aggregation, and calculations to derive the necessary OEE metrics. QCA Systems used cloud-based data processing tools and SQL queries to transform the data efficiently.

QCA Systems connected Power BI to the cloud data warehouse and configured the necessary data connections to pull the SCADA data in real time. We utilized Power BI’s data modeling capabilities to create relationships between tables, define measures, and design visualizations for OEE reporting.

QCA Systems optimized the performance of the OEE report in Power BI by considering factors such as data compression, query optimization, and efficient use of data caching techniques. We ensured that the report responded quickly and provided real-time insights for operational decision-making.

QCA Systems established monitoring mechanisms to track the health and performance of the data transfer, cloud data warehouse, and Power BI report. We implemented regular maintenance activities, such as data backups, security updates, and version control, to ensure the system operates smoothly.

By adopting a holistic approach to design and management, leveraging appropriate monitoring methods, and providing ongoing support, QCA Systems helped to ensure the reliability, security, and performance of the OT network. This enabled the customer to optimize their operational processes, enhance efficiency, and achieve their desired outcomes.

Key Results

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QCA Systems Implement an Operating Equipment Efficiency (OEE) report in Power BI

QCA Systems integrated legacy systems
QCA Systems applied the best security practices available.
Network complexity is high, so details are important.
The project was done with collaboration between IT and OT resources.
Maintenance and Upgrades are part of the support plan.
Network security was paramount in the project.

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