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Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System
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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. ► 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

  3. 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

  4. 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

  5. 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

  6. 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

  7. 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

  8. 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

  9. 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

  10. 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

  11. 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

  12. 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

  13. 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

  14. 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

  15. 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

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

  17. 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

  18. 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

  19. 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

  20. 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

  21. 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

  22. 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

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

  24. 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

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

  26. 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

  27. 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

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

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

  30. 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

  31. 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

  32. 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

  33. 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

  34. 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

  35. Report Control Bar – Navigating your Reporting At the bottom of every Report there will be a Control Bar. Each part of the Report Control Bar is described below www.matrixcontrols.net

  36. MKMS Reports - Knitter Efficiency - Another Look Knitter Efficiency % 801 (Knitter) Time (Hr) Sum of @ Worked Hours Sum of @ Lost Hours Average of Knitter Eff. www.matrixcontrols.net

  37. MKMS Reports – Knitter Shift Production Summary www.matrixcontrols.net

  38. MKMS Reports – Detailed Fabric Piece Report www.matrixcontrols.net

  39. Reasons to Train Hard and Optimize MKMS Usage Five Areas of Production System Savings: 1) Yarn Rate Monitoring - Savings by preventing over/under feeding machines 2) Machine Speed Increases - Allows for additional production 3) Increased Efficiency - Through Downtime Reduction 4) Fabric Defect Detection - Reduced waste, Increased quality, and orders 5) Yarn Quality Improvements- Increased efficiency and fabric quality www.matrixcontrols.net

  40. An Example of Potential Savings with MKMS: In this Sample Scenario, Matrix installed its MKMS System on 25 Circular Knitting Machines. Savings were calculated, and we then included the effects of better fabric quality, leading to increasing orders. Our sample knitting mill had to expand to 40 machines, and then increase production to 7 days per week. The results were impressive. Production Scenarios www.matrixcontrols.net

  41. The Numbers Show It, and So Will Yours: Enjoy MKMS ! Production Savings Yearly Savings 5 Year Savings www.matrixcontrols.net

  42. …and The Graphics Show It Also: Enjoy MKMS ! U.S. $s In Seven Years This 25 Machine Mill’s Savings Exceeded 1.2 Million $ INCREASING REVENUE OVER 7 YEARS IN U.S. $ www.matrixcontrols.net

  43. Another Look at the 5 System Savings: Enjoy MKMS! www.matrixcontrols.net

  44. MKMS -Reaching Your Full Potential- Enjoy MKMS! Potential Yearly Sales in Three Production Scenarios: 25 Machines, 40 Machines, and 40 Machines + 100 Days www.matrixcontrols.net

  45. … and More- Other MKMS Features to Help You: Other Features: ► Click and Drag Machine Icons on Real-time Display ► Real-time RPM, Yarn Rate and Declaration Status Display ► Masking of Machines with Declarations on Real-time Display ► Ability to Build Trial Sets for Yarn, Needle, and Machine Tracking ► Shift Schedule for Multi-week Shift Rotations www.matrixcontrols.net

  46. … and More- Other MKMS Features to Help You: Even More Features: ► Enhanced Set Building Abilities ► Motivational Pay Factoring for Knitter Pay ►Custom Downtime Calculations to be Used for Knitter Incentives ► Multi-lingual Software Availability Additional Options: www.matrixcontrols.net

  47. Additional “MKMS” Options to Enjoy: Additional Options: ► Payroll System Interface ► Roll Weight Calculation ► Bar Code Ticket Printing ► Greige Inspection/Mending Interface ► Error Sourcing Analysis www.matrixcontrols.net

  48. Additional “MKMS” Options to Optimize Your Plant The Package Becomes Complete with ■ Automated Production Scheduling and ■ Business and Production Intelligence www.matrixcontrols.net

  49. Automated Production Scheduling Automated Sequencing Integrated Shop Floor Product Scheduling www.matrixcontrols.net

  50. Automated Production Scheduling Auto Scheduling allows the Scheduler to: ►Optimize on-time order completion ► Maximize the overall production efficiency ► Optimize the production schedule ►Minimize changeovers and set-up time ► Schedule orders on optimal resource ► Provide immediate notification of production issues ► Build a flexible and responsive production schedule, and actionable status reporting ►Control Work-In-Process Inventory www.matrixcontrols.net