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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Page 1: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

Welcome to Matrix Controls

and

MKMSMatrix Knit Monitoring System

Page 2: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

Matrix Controls

F-1000 Monitor MKMS Management Software

Infrared, High Resolution, Threshold Adjustable, Self Cleaning, Defect Scanning

Total Knit Control

Fabric Scan

Page 3: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

MKMS allows your company and workers to enjoy:

► 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

www.matrixcontrols.net

Page 4: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

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

Conv. Costs

Overhead& Cost of Capital

Materials

Cost per lb.

Margin

Knitting Value Chain

www.matrixcontrols.net

Page 5: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

Train, Learn and Enjoy:

www.matrixcontrols.net

▪ 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…

Page 6: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

Page 7: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

How MKMS Works:

www.matrixcontrols.net

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

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

Page 8: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS’ Yarn Rate Monitoring:

“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.

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 !

Page 9: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Scanning, Yarn Rate Monitoring and the F-1000 Monitor Controller

Introducing the MKMS’ Human-Machine Interface F-1000 Monitor/F-

1000

Yarn Rate Transducers

Page 10: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

MKMS impacts each of these areas to increase plant productivity.

Page 11: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Reduces 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

Page 12: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Reduces 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. 

Page 13: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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 additionalmodules to assist your house-keeping efforts:

■ Advanced PM (Pre- ventive Maintenance Scheduling

■ Machine Diagnostic Software-features voice announcing and failure analysis

Page 14: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Allows You to Increase Your Machine Speed By monitoring machine production efficiency and quality, MKMSallows 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

Page 15: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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)

Page 16: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

■ The MKMS 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

MKMS’ RTDISP and AUTODA

Page 17: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

■ 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

User Friendly, Point and Click to Color-Coded Screens and Reporting

Page 18: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS’s RTDISPCurrent Status of your Entire Knitting Mill Plant Floor

Page 19: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

Shift Data : • Revolutions

• Top, Bottom, Needle, Stops• Efficiency • Missed Inspection

Piece Data :

• Revolutions in the piece• Defects and their locations• Piece number and dates • Number of unknown defects

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

Page 20: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

A Knitting Machine at a glance:

Entire Knitting Mill Floor

Individual Machine Status Icon

Machine #

RPM (red=out of tolerance) (green=in tolerance)

Yarn Rate (red=out of tolerance)

Declaration Status (red when declaration code is entered)

Color shows the Status. Box will show either Effic-iency, Log Status or Style ID.

Page 21: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Current Status Screen

Click and view the Current Status Screen below:

Configuration

Retrieve Data

Hardware SetUp

Exit

VIEW:

► F1000/Operator I.D.

► Communication Setting

► Current F1000 Status

► Configuration Data

► Retrieve Data

► Set-up Hardware

Page 22: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Current Configuration ScreenConfiguration

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

Page 23: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Retrieve Data ScreenRetrieve Data

Click and view the Retrieve Data Screen below:

Retrieve

► Shift Data

► Piece & Multi-piece

► Operator Data

► Machine/Operator Data Input DataClick Shift and enter data.

Page 24: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

Hardware Set-up ScreenHardware Set-up

Click and view the Hardware Set-up Screen below:

HardwareSettings

► Enable Machine

► Disable Machine

► Stop Machine

► Set External Lamps

www.matrixcontrols.net

Page 25: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

MKMS Software’s Main Menu

---- MKMS

www.matrixcontrols.net

Help

AboutMKMS

Save FloorLayout

Refresh

Exit

EditDefects

ShiftSet-up

OperatorSet-up

StatusSet-up

DeclareSet-up

Extended Shift Set-up

Language

EfficiencySee Slide 32

Administration See Slide 33

Current Shift ►

Efficiency ►

Machine ►

Piece Report

Detail Piece

Auto Downtime

Detail Auto Down

Downtime

Detail Downtime

Declaration

Stops Report

Knitter Shift

Style Production

Log On

Log Off

Efficiency

Log Status

Style Information

Declarations

Plant 1

Plant 2

Plant 3

Send Style See Slide 34

Page 26: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

A Main Menu Tour

Efficiency

Efficiency Screen

► Mill Efficiency

► Production

► Knitter Efficiency

► Machine Efficiency

► Style Efficiency

Page 27: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

A Main Menu TourAdministration

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

Page 28: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

A Main Menu Tour

Employee Log ON/OFF and Security (Passwords and Levels)

Circular Knits Inc.

Page 29: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

A Main Menu Tour

Send Style – Fabric Settings

Circular Knits Inc.

Page 30: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

A Main Menu Tour

► 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

Send Style – Fabric Settings

Page 31: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

A Main Menu Tour - Status SetupStatus Set-up:

Page 32: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

Page 33: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

The Knitter/Operator Reacts by Entering a Defect Code

Page 34: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

The Operator Also Enters Downtime Declaration Codes

Declaration Code = the Reason for a Machine Malfunction

Page 35: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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.

F-1000 Green Light, alerts Mechanics to Pre-set Inspections

Matrix F-1000

CIRCULAR KNIT

Page 36: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

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.

Blinking Green Light, Alerts Operators to Pre-Doff & Doff

F1000 Displays-Doff & Pre-Doff

www.matrixcontrols.net

Matrix F-1000

CIRCULAR KNIT

Page 37: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Blinking Green Light, alerts Operators to Pre-Doff & Doff

PRE-DOFF DOFF ROLL

Visual Displays

Matrix F-1000

Matrix F-1000

Page 38: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

140 F-1000 Visual Displays-A Quick Glance at Examples

Visual Displays

DROP STITCH

LOGGED ON

Page 39: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.netwww.matrixcontrols.net

140 F-1000 Visual Displays-A Quick Glance at Examples

Visual Displays

RUN STOPDROP STITCH

Page 40: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.netwww.matrixcontrols.net

140 F-1000 Visual Displays-A Quick Glance at Examples

Visual Displays

NEEDLE RUN F-2000

Page 41: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.netwww.matrixcontrols.net

140 F-1000 Visual Displays-A Quick Glance at Examples

Visual Displays

PRESS OFF MACHINE #

Page 42: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.netwww.matrixcontrols.net

140 F-1000 Visual Displays-A Quick Glance at Examples

Visual Displays

OIL FLUSH STYLE #

Page 43: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.netwww.matrixcontrols.net

140 F-1000 Visual Displays-A Quick Glance at Examples

Visual Displays

SEAM BYPASS

DEFECT LVL

Page 44: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.netwww.matrixcontrols.net

140 F-1000 Visual Displays-A Quick Glance at Examples

Visual Displays

LOG OFF AUTO CAL

Page 45: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

F-1000 Visual Displays - Other Typical Daily Displays

Top Stop

Bottom Stop

Needle Stop

Operator Stop

Doff Roll

Fabric Defect

Pre-Doff

Check Yarn Rates

Too Many Defects

Patrol

No Operator Assigned

Invalid Style Number

Low Air Pressure

Page 46: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Supervision and Analysis Made Easy – F1000 Reports

Current Shift

Efficiency

Machine

Piece Report

Detail Piece

Auto Downtime

Detail Auto-Down

Types of Reports

Downtime

Detail – Downtime

Declaration

Stops Report

Knitter Shift

StyleProduction

Page 47: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Reporting – Some Examples : Detailed Piece ReportPiece 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

Page 48: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.netwww.matrixcontrols.net

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

Page 49: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

Page 50: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Reports-Example: Exceptions by Machine Efficiency ReportKnitting 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

Page 51: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

Page 52: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

Some MKMSActual Reports

Knitter Efficiency

www . matrixcontrols . net

Kn

itter I.D

.

Enjoy easy to visualize

displays of your

Knitter’s efficiency for

the week

MKMS Reporting

Page 53: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Reports - Knitter Efficiency - Another LookK

nitte

r Effi

cie

ncy %

801 (Knitter)

Sum of @ Worked Hours Sum of @ Lost Hours Average of Knitter Eff.

Page 54: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Reports – Knitter Shift Production Summary

Knitters Knitters Knitters Knitters

Knitter ID Machine # Revolutions Pay Efficiency Run Time (hr:min) Stop Time (hr:min)

2003

709 37,905 0.00 91.5% 10:46 01:00

804 28,169 0.00 84.8% 10:04 01:48

805 35,002 0.00 91.3% 10:50 01:02

808 36,116 0.00 92.7% 10:33 00:50

Totals: 137,192 0.00 90.0% 42:13 04:40

2004

506 36,783 0.00 82.8% 09:37 02:00

507 45,326 0.00 82.6% 09:35 02:01

509 35,353 0.00 83.1% 09:48 02:00

510 33,980 0.00 89.6% 10:32 01:13

Totals: 151,442 0.00 84.5% 39:32 07:14

Page 55: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Style Shift Date # of Machines Total Revs Total Weight Produced Efficiency

1573-30D50 A 7/2/2003 3 32121 2083 LBS 43.38%

1703-24R24 A 7/2/2003 1 30059 835 LBS 91.94%

1703-26R46 A 7/2/2003 1 27851 935 LBS 85.97%

1703-30R80 A 7/2/2003 1 20005 1007 LBS 80.56%

1707-20T20 A 7/2/2003 1 18305 385 LBS 87.22%

1721-15865 A 7/2/2003 1 38538 486 LBS 82.22%

1721-19879 A 7/2/2003 1 4009 76 LBS 75.69%

1721-20O50 A 7/2/2003 1 32436 709 LBS 84.58%

MKMS Reports – Production Weight Summary (by Style)

Shift A

Page 56: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Reports – Knitting Machine Stop Report Shift Date Shift Machine# Start Time End Time Stop Type Total Minutes

12/1/2004 Total Minutes: 29

A Total Minutes: 29

001 Total Minutes: 29

Doff Stop Total Minutes: 4

12/1/2004 A 001 8:53:20 8:57:45 Doff Stop 4

Patrol Stop Total Minutes: 0

12/1/2004 A 001 8:34:00 8:34:30 Patrol Stop 0

PreDoff Stop Total Minutes: 0

12/1/2004 A 001 8:49:04 8:49:19 PreDoff Stop 0

Top Stop Total Minutes: 25

12/1/2004 A 001 6:52:24 6:54:20 Top Stop 2

12/1/2004 A 001 6:54:29 6:55:11 Top Stop 1

12/1/2004 A 001 6:58:46 7:01:06 Top Stop 3

12/1/2004 A 001 7:04:10 7:05:02 Top Stop 1

12/1/2004 A 001 7:37:29 7:38:59 Top Stop 1

12/1/2004 A 001 7:43:45 7:48:29 Top Stop 5

12/1/2004 A 001 7:48:48 7:49:59 Top Stop 1

12/1/2004 A 001 9:13:38 9:17:25 Top Stop 4

12/1/2004 A 001 9:21:11 9:22:19 Top Stop 1

12/1/2004 A 001 10:37:34 10:43:44 Top Stop 6

User Stop Total Minutes: 0

12/1/2004 A 001 6:47:25 6:47:43 User Stop 0

Page 57: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Reports – Detailed Auto Downtime Report

Detailed Auto Downtime

5/1/08

Shift: All Machine: All

Downtime Code: All

Page 58: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

MKMS Reports – Detailed Fabric Piece Report

Page 59: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

Page 60: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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.

25 Machines-251 Days/Year CIRCULAR

40 Machines-251 Days/Year KNIT

40 Machines- 351 Days/Year

CONTROL

Production Scenarios

Page 61: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

The Numbers Show It, and So Will Yours: Enjoy MKMS !

Production Savings Yearly Savings 5 Year Savings

Page 62: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

…and The Graphics Show It Also: Enjoy MKMS !

INCREASING REVENUE OVER 7 YEARS IN U.S. $

In Seven Years This 25 Machine Mill’s Savings Exceeded 1.2 Million $

U.S. $s

Page 63: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Another Look at the 5 System Savings: Enjoy MKMS !

Page 64: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

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

Page 65: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

… 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

Page 66: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

… 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:

Page 67: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Additional “MKMS” Options to Enjoy:

Additional Options:

► Payroll System Interface

► Roll Weight Calculation

► Bar Code Ticket Printing

► Greige Inspection/Mending Interface

► Error Sourcing Analysis

Page 68: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

www.matrixcontrols.net

Additional “MKMS” Options to Optimize Your Plant

The Package Becomes Complete with

■ Automated Production Scheduling and

■ Business and Production Intelligence

Page 69: Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

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Automated Production Scheduling

Automated Sequencing

Integrated Shop Floor Product Scheduling

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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

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Automated Production Scheduling

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Auto Scheduling allows your Company to:

► Get the most orders out

► Get high priority customer orders out

► Meet the maximum number of promise dates

► Minimize inventory

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MQM - Visual Displays-A Quick Glance at Examples Order Monitoring Screen:

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MQM - Visual Displays-A Quick Glance at Examples Order Information by Machine:

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Business and Production Intelligence

No matter where the data is, or from what source it originates

With the Matrix Dashboard, operational data is easily integrated with information from other parts of the business, making it possible to gain better visibility into production efficiency and product profitability. You can… 

► Drill down-and-through, to access other data sources and reports for more detail about what the Dashboard shows you

▪ Access by product, machine, customer, etc.

▪ Access operational or financial data, and drill down into the lowest levels

► Set alerts and notifications to keep you aware of when a metric changes status

► Empower anyone in your organization to monitor and analyze performance with ease

► Easily customize for any desired type of information delivery

 

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Business and Production Intelligence

When do you want the bad news? A.S.A.P. (as soon as possible)

► Remember, in manufacturing, bad news early, is good news

► Having the right technology, capturing the right data is only one part of

the solution

► You must know when things are going wrong, without having to wait for the phone to ring, or wade through reports

► The sooner you know a machine is broke, the sooner you can re-plan

► The sooner you know raw materials are not available, the more time you have to react

► The Matrix Dashboard will email you as soon as any of your pre- defined events happen (positive or negative)

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“MKMS” - “Auto Scheduling” - “ Business Intelligence”

MKMS allowed you to collect crucial data. Now integrate that data. Integrate it, into an Automated Production Scheduling System. Auto Scheduling allows you to optimize machine usage, thereby allowing less set-up time, longer run times, and always choosing the right machine for the job.

Now Optimize Fully, and take the next step. Integrate your captured data into Business Intelligence, and maximize your corporate performance management. Enjoy, “Easy access, no matter where, or from what source”.

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Question: Who wins with MKMS ? Answer: Everyone!

MKMS- Matrix Knit Monitoring System

Who wins:

■ Knitters Win!

■ Mechanics Win!

■ Supervisors Win!

■ Knitting Production Managers Win!

■ Plant Managers Win!

■ Your Company Wins!

■ The Textile Industry Wins!

■ Your Customers Win!

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Thank you Very Much!

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Matrix Controls thanks you for your time and attention. We look forward to working with you.

M A T R I X =C O N T R O L

Matrix Defined-“A rectangular array of numerical data-data Matrix has controlled for 50 years to save you money!”