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Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System. Matrix Controls. Total Knit Control. . . MKMS Management Software. F-1000 Monitor. Fabric Scan. Infrared, High Resolution, Threshold Adjustable, Self Cleaning, Defect Scanning.

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Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System


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    1. Welcome to Matrix Controlsand MKMSMatrix Knit Monitoring System

    2. Matrix Controls Total Knit Control   MKMS Management Software F-1000 Monitor Fabric Scan Infrared, High Resolution, Threshold Adjustable, Self Cleaning, Defect Scanning

    3. ► A more peaceful and produc- tive knitting mill floor ☼ ► Defect detection ▪ Reduced Waste ▪ Increased Quality ▪More Satisfied Customers ► Reduced downtime, ↑Efficiency ► Machine speed increases, and more production ► Yarn rate monitoring, prevent- ing machine overfeeds ► Determining the quality of yarn from your suppliers ► Happier workers, less turnover MKMS allows your company and workers to enjoy: www.matrixcontrols.net

    4. Take another look: • Increase productivity through enhanced scanning, monitoring and control with: • Lower cost • Reduce Capital Expenditures • Faster and more timely production • More accurate results Cost per lb. Margin Overhead & Cost of Capital Conv. Costs Materials Knitting Value Chain www.matrixcontrols.net

    5. Train, Learn and Enjoy: ▪ Change: ▪ Like any tool, in order to maximize production and efficiency, the Matrix Knit Monitoring System requires proper operation. It’s not hard, but Matrix understands that we all are reluctant to change. But that’s okay, because Matrix also knows that once your company and employees realize their work efforts will be easier, more productive, and more profitable, change will be • welcomed and come fast. • ▪ 50 Years: • ▪ Fifty years of Circular Knit Control has given Matrix the tools to teach, train and • successfully implement your MKMS system. Our Project Managers, Engineers • and staff, will guide your personnel towards profits many companies before • have enjoyed. • ▪ Possible Results: • ▪ Reduction of total defects by 30%, and reduction of inspections from 35% to • 5%, along with improved production scheduling of fabric rolls, as the mill • converts to ‘knit-to-order’. And more… www.matrixcontrols.net

    6. Train, Learn and Enjoy…and Save Time, Money and Reduce Stress ▪ Even better: Matrix has gone one step further in making your life easier, and now offers the Auto- mated Scheduling and Business Intelligence modules, as additions to our MKMS package. Auto re-route, and the Matrix Dashboard’s immediate data availability and alerts, take manufacturing efficiencies to a new level. Let’s see how MKMS works  ▪ Even better: Matrix has gone one step further in making your life easier, and now offers the Auto- mated Scheduling and Business Intelligence modules, as additions to our MKMS package. Auto re-route, and the Matrix Dashboard’s immediate data availability and alerts take manufacturing efficiencies to a new level. Let’s see how MKMS works  www.matrixcontrols.net

    7. How MKMS Works: Fabric Defect Detection: ► Defect mapping capabilities ▪ Production stops after programmable number of defects are exceeded in roll ▪ Scanners are threshold adjustable--you decide what defects are tolerable ►Defect location assignment by revolution count ► Operator periodic alerts to visually inspect ► Running defect reduction to less than 12 inches ► Reduces labor-intensive processes in defect and greige inspection ► DOGS or Dirt, Oil and Grease scans recorded and reported to maintenance ► Self-cleaning scanner heads, and immediate machine shut down, if fabric pulls off scanner Detection On: • Jersey • Rib • Rashel• Mesh • Fleece • Terry • Interlock • Spandex • Thermal Installed On: • Vanguard • Fukuhara • Keum Yong • Mayer • Monarch • Nova • Pai Lung • Ssang Yung • Terrot www.matrixcontrols.net

    8. MKMS’ Yarn Rate Monitoring: Continuous Yarn Rate Monitoring: ► Prevents Overfeeding and Underfeeding—both lead to poor quality fabric ▪ Overfeeding causes a porous fabric that has loops, which will shrink and use excess yarn ▪ Underfeeding produces a heavy, dense and narrow fabric, and also wastes yarn ►Allows strict tolerances to be maintained ► Time spent on periodic audits can be eliminated ► Reduction of unnecessary dying and finishing of off quality fabric ► Allows you to detect off quality yarn leading to requests from vendors for higher quality yarn ► Reduces time lost (extra labor and downtime) dealing with poor quality fabric ► Your customers will enjoy great fabric quality, and you will enjoy new orders, and new customers! • “We were amazed at how many machines were out of tolerance when the MKMS was initially turned on” • Knitting Technical • Service Manager • Case study: One 300 machine installation found 60% out of tolerance, and showed a $600,000 overall cost savings. www.matrixcontrols.net

    9. Scanning, Yarn Rate Monitoring and the F-1000 Monitor Controller Introducing the MKMS’ Human-Machine Interface Scanners F-1000 Monitor/F-1000 Yarn Rate Transducers www.matrixcontrols.net

    10. MKMS Improves Productivity and Efficiency Knitting Mills measure productivity in a number of ways, but in any mill the goal is to produce more first quality output at a: ► Lower Cost ► With Lower Capital Employed ► Faster Production Rate ► Greater Accuracy MKMSimpacts each of these areas to increase plant productivity. www.matrixcontrols.net

    11. MKMSReduces Machine Stops Machine downtime is typically caused by fabric defects, yarn related stops, style changes/set-up times and preventive maintenance. The MKMS reduces the number of fabric defects and yarn related stops both directly and indirectly, by ► Setting limits to the number of point defects and forcing the operator to take action, the total number of repeated point defects is reduced ► Providing a Scheduled Maintenance Plan based on accurate counts of machine revolutions and knit element life, to reduce the number of defects due to improperly timed preventive maintenance ► Setting limits to the number of point defects and forcing the operator to take action, substandard yarn can be flagged within hours and corrective action taken immediately www.matrixcontrols.net

    12. MKMSReduces Machine Downtime The length of a stop is influenced by the type of stop and the operator’s response. MKMS combined with the visual display of the F-1000 provides ► The operator as well as production management, immediate knowledge of the stop reasons, thereby helping the operator to pinpoint the remedy to the particular stop. ► The operator the ability to prioritize the remediation of the stop when multiple machines are simultaneously stopped. ► Stop-time reporting, which offers feedback to the operator both generally as well as compared to other plant benchmarks to reduce the length of each particular stop. www.matrixcontrols.net

    13. MKMS’ House-Keeping and Preventive Maintenance Effective and clean machine maintenance decreases down- time, while reducing lint build up which optimizes quality production: ► MKMS’ automatic oil and air control maximizes cleanliness, while reducing oil and air usage ►The result = less lint buildup, thereby reducing defects ► Doff control with Pre-Doff, produces a cleaner end of roll, leading to reductions in wasted fabric ► Knitting element life is monitored on a revolution basis to assist in Scheduling Preventive Maintenance ► Mechanics are assisted with Automatic Scanner Calibra- tion, Auto Yarn Rate Measurement & Speed Monitoring ► Oil Flush and Sinker Air Purge are sequenced auto- matically ► Rotating Needle Blowers can be sequenced for maximum cleaning, reducing time operators spend blowing off knitting elements Matrix offers additional modules to assist your house-keeping efforts: ■ Advanced PM (Pre- ventive Maintenance Scheduling ■ Machine Diagnostic Software-features voice announcing and failure analysis www.matrixcontrols.net

    14. MKMS Allows You to Increase Your Machine Speed By monitoring machine production efficiency and quality, MKMS allows machine speed to be increased. Machine speed in- creases of 5 rpm are typically seen, which = Thousands $s Saved Annually. ► MKMS sets tolerances and can stop machines from a PC, when out of tolerance conditions occur ► Quality and Efficiency are maintained with all increases, and production increases tremendously, as do profits MKMS offers:: ■ Increased Speed ■ Increased Efficiency ■ Increased Quality ■ Increased Orders ■ Increased Profits www.matrixcontrols.net

    15. What you see: The Matrix Knit Monitoring System (MKMS) consists of two sub-systems: ► The Matrix Real-time Display System (RTDISP) and the ► The Matrix Auto Data Acquisition System (AUTODA) www.matrixcontrols.net

    16. MKMS provides personnel with: ■ MKMS’ Software Coding provides the management team a real-time overview of production status, with immediate drill down capability to an individual machine/style/operator ■ TheMKMS Software allows flexibility for custom reporting for additional productivity enhancements and options ■ The MKMS Software allows the department management team to view overall downtime occurrences to minimize opportunities lost ■ The MKMS Software can integrate downtime and revolution information with the plant payroll and other internal systems, providing improved payroll calculations and facilitating pay for performance. It does so: Accurately, rapidly, with less man-power, and improves payroll fairness and accuracy Color MKMS’ RTDISP and AUTODA    www.matrixcontrols.net

    17. MKMS’s RTDISP (real-time display system) Point and Click your way to all of below: ■ View entire Plant’s Knitters, Machine and Knitter efficiencies, machine exceptions and more… ■ Complete access to utilities for system configuration ■ Configure individual F-1000s ■ Retrieve data from individual F1000s ■ Build Knitter Set Assignments rapidly User Friendly, Point and Click to Color-Coded Screens and Reporting ■ Machine Preventive Maintenance Scheduling ■ Log knitters and mechanics ON and OFF knitting machines ■ Create a Style Database and download styles to individual F1000s ■ Create a Knitting Machine Information Database ■ Provision for database back-ups ■ Priority Screen, which prioritizes machines/orders www.matrixcontrols.net

    18. MKMS’s RTDISP Current Status of your Entire Knitting Mill Plant Floor www.matrixcontrols.net

    19. MKMS’s AUTODA (Auto Data Acquisition System) ► Automatic retrieval of F1000 data at user specified intervals ►AUTODA is 100% independent from any human tasks once the system is started Data includes: Machine Status: • Machine Running • Top & Bottom Stop • Needle Stop • Auxiliary Stop • User & Host Stop • Missed Inspection • Pre-Doff & Doff • Fabric Defects • Scanner Data • No Revolution Pulse • Calibration & System Error • Machine to Start Piece Data : Shift Data : • Revolutions in the piece • Defects and their locations • Piece number and dates • Number of unknown defects • Revolutions • Top, Bottom, Needle, Stops • Efficiency • Missed Inspection Style Data : • Style number and revolutions • Number of each type of defect • Number of known defects • Number of unknown defects • Top, bottom, needle & auxiliary stops www.matrixcontrols.net

    20. A Knitting Machine at a glance: •  •  •  Entire Knitting Mill Floor Individual Machine Status Icon Machine # RPM (red=out of tolerance) (green=in tolerance) Color shows the Status. Box will show either Effic-iency, Log Status or Style ID. Yarn Rate (red=out of tolerance) Declaration Status (red when declaration code is entered) www.matrixcontrols.net

    21. Current Status Screen Click and view the Current Status Screen below: VIEW: ► F1000/Operator I.D. ► Communication Setting ► Current F1000 Status ► Configuration Data ► Retrieve Data ► Set-up Hardware Configuration Retrieve Data Hardware SetUp Exit www.matrixcontrols.net

    22. Current Configuration Screen Configuration Click and view the Current Configuration Screen below: Click Arrow to select F1000 View all your settings ► Yarn rates ► Revolutions ► Messaging ► Oil/Air Purge ► Security www.matrixcontrols.net

    23. Retrieve Data Screen Retrieve Data Click and view the Retrieve Data Screen below: Retrieve ► Shift Data ► Piece & Multi-piece ► Operator Data ► Machine/Operator Data Input Data Click Shiftand enter data. www.matrixcontrols.net

    24. Hardware Set-up Screen Hardware Set-up Click andview the Hardware Set-up Screen below: Hardware Settings ► Enable Machine ► Disable Machine ► Stop Machine ► Set External Lamps www.matrixcontrols.net

    25. MKMS Software’sMain Menu ---- MKMS Help About MKMS Save Floor Layout Refresh Exit Edit Defects Shift Set-up Operator Set-up Status Set-up Declare Set-up Extended Shift Set-up Language Log On Log Off Current Shift ► Efficiency ► Machine ► Piece Report Detail Piece Auto Downtime Detail Auto Down Downtime Detail Downtime Declaration Stops Report Knitter Shift Style Production Send Style See Slide 34 Administration See Slide 33 Efficiency Log Status Style Information Declarations Plant 1 Plant 2 Plant 3 Efficiency See Slide 32 www.matrixcontrols.net

    26. A Main Menu Tour Efficiency Efficiency Screen ► Mill Efficiency ► Production ► Knitter Efficiency ► Machine Efficiency ► Style Efficiency www.matrixcontrols.net

    27. A Main Menu Tour Administration Add/Edit Knitters Add/Edit Mechanic Build Sets from Layout Assign Priority From Layout Knitter Log ON/OFF Edit Knitting Machines Download to F1000 Add Down Time Retrieve Shift Data Edit Styles Style Master Build Trial Sets Set Polled From Sets Knitter Reassignment Security Levels Password Style Update MKMS www.matrixcontrols.net

    28. A Main Menu Tour Employee Log ON/OFF and Security (Passwords and Levels) Circular Knits Inc. www.matrixcontrols.net

    29. A Main Menu Tour Send Style – Fabric Settings Circular Knits Inc. www.matrixcontrols.net

    30. A Main Menu Tour Send Style – Fabric Settings ► Yarn Parameters ► Machine Parameters ► Defect Thresholds ► Inspection Settings ► Air/Oil Settings ► # of Feeds ► # of Needles ► Stitches per Inch ► Wales per Inch ► Greige Expected Yield ► Punch Weight ► Pay Factor per Revs www.matrixcontrols.net

    31. A Main Menu Tour - Status Setup Status Set-up: www.matrixcontrols.net

    32. F-1000 Blue Light, alerts Knitter to Fabric Defects This F-1000 has shut down the knitting machine because of fabric defects. The operator sees the blue light and responds by entering the proper defect code (next slide), after inspecting the defective fabric. The operator then restarts the machine. CIRCULAR KNIT www.matrixcontrols.net

    33. The Knitter/Operator Reacts by Entering a Defect Code www.matrixcontrols.net

    34. The Operator Also Enters Downtime Declaration Codes Declaration Code = the Reason for a Machine Malfunction www.matrixcontrols.net

    35. F-1000 Green Light, alerts Mechanics to Pre-set Inspections The F-1000 alerts the Mechanic with a Solid Green Light, to Pre-set Inspections. These Inspections are set according to a specified number of Machine Revolutions. F-1000 controlled air/oil purge offer added housekeeping options. Advanced Preventive Maintenance Modules are also available. CIRCULAR KNIT Matrix F-1000 www.matrixcontrols.net

    36. Blinking Green Light, Alerts Operators to Pre-Doff & Doff The F-1000 alerts the Operator with a Blinking Green Light, to Pre-Doff, or Doff, depending on the F1000’s visual display. This ensures rapid restarts of production, with little wasted time, and again increases housekeeping efficiencies. CIRCULAR KNIT Matrix F-1000 F1000 Displays-Doff & Pre-Doff www.matrixcontrols.net

    37. Blinking Green Light, alerts Operators to Pre-Doff & Doff Visual Displays DOFF ROLL PRE-DOFF Matrix F-1000 Matrix F-1000 www.matrixcontrols.net

    38. 140F-1000 Visual Displays-A Quick Glance at Examples Visual Displays LOGGED ON DROP STITCH www.matrixcontrols.net

    39. 140F-1000 Visual Displays-A Quick Glance at Examples Visual Displays DROP STITCH RUN STOP www.matrixcontrols.net www.matrixcontrols.net

    40. 140F-1000 Visual Displays-A Quick Glance at Examples Visual Displays F-2000 NEEDLE RUN www.matrixcontrols.net www.matrixcontrols.net

    41. 140F-1000 Visual Displays-A Quick Glance at Examples Visual Displays MACHINE # PRESS OFF www.matrixcontrols.net www.matrixcontrols.net

    42. 140F-1000 Visual Displays-A Quick Glance at Examples Visual Displays STYLE # OIL FLUSH www.matrixcontrols.net www.matrixcontrols.net

    43. 140F-1000 Visual Displays-A Quick Glance at Examples Visual Displays DEFECT LVL SEAM BYPASS www.matrixcontrols.net www.matrixcontrols.net

    44. 140F-1000 Visual Displays-A Quick Glance at Examples Visual Displays AUTO CAL LOG OFF www.matrixcontrols.net www.matrixcontrols.net

    45. F-1000 Visual Displays - Other Typical Daily Displays www.matrixcontrols.net

    46. Supervision and Analysis Made Easy – F1000 Reports Types of Reports Current Shift Efficiency Machine Piece Report Detail Piece Auto Downtime Detail Auto- Down Downtime Detail – Downtime Declaration Stops Report Knitter Shift Style Production www.matrixcontrols.net

    47. Reporting – Some Examples : Detailed Piece Report Piece Report Provides: ► Machine #, date, shift, piece ID ► Revolutions, known /unknown defects ► Detailed defect data • Defect ID • Defect Message • Location of Defect ■ Choose your range of • Pieces • Machines • Shifts • Dates www.matrixcontrols.net

    48. Reporting – Some Examples : Declaration Report Declaration Report Provides ► For selected Date, Shift, and Machine, you’ll see: • Start and End Time • Total Time • End Type ■ You may choose: • Specific Shifts • Specific Machines • Specific Declarations • Specific Dates/ranges Also Choose the End Type: • Completed Declarations • Canceled Declarations • or Both www.matrixcontrols.net www.matrixcontrols.net

    49. Reporting – Some Examples : Stop Report Stop Report Provides ► For selected Date, Shift, and Machine, you’ll see: • Start and End Time • Total Time • End Type ► Limit the report to a spe- cific date range, or all dates. ■ You may choose: • Specific Shifts • Specific Machines • Stop Types, or All Stops www.matrixcontrols.net

    50. Reports-Example: Exceptions by Machine Efficiency Report Knitting machines - Exceptions by Machine Efficiency It Reports: ■ The current efficiency for machines currently in production along with their total exception stops, shift revolutions, and the knitter assigned to each machine. This re- port can also be printed for: • All machines sorted by efficiency increasing • All machines sorted by efficiency decreasing • Production machines sorted by efficiency increasing • Production machines sorted by efficiency decreasing • Production machines with an efficiency < or > X • By knitter set number www.matrixcontrols.net