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Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System.

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Presentation on theme: "Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System."— Presentation transcript:

1 Welcome to Matrix Controls and MKMS Matrix Knit Monitoring System

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

3 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

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 Conv. Costs Overhead & Cost of Capital Materials Cost per lb. Margin Knitting Value Chain

5 Train, Learn and Enjoy: Change: Like any tool, in order to maximize production and efficiency, the Matrix Knit Monitoring System requires proper operation. Its not hard, but Matrix understands that we all are reluctant to change. But thats 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…

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 Dashboards immediate data availability and alerts, take manufacturing efficiencies to a new level. Lets 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 Dashboards immediate data availability and alerts take manufacturing efficiencies to a new level. Lets see how MKMS works

7 How MKMS Works: 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

8 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 Underfeedingboth 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 !

9 Scanning, Yarn Rate Monitoring and the F-1000 Monitor Controller Introducing the MKMS Human-Machine Interface F-1000 Monitor/F-1000 Yarn Rate Transducers

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 MKMS impacts each of these areas to increase plant productivity.

11 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

12 MKMS Reduces Machine Downtime The length of a stop is influenced by the type of stop and the operators 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.

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

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

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)

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 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

17 MKMSs RTDISP (real-time display system) Point and Click your way to all of below: View entire Plants 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

18 MKMSs RTDISP Current Status of your Entire Knitting Mill Plant Floor

19 MKMSs 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

20 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.

21 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

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

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 Shift and enter data.

24 Hardware Set-up Screen Hardware Set-up Click and view the Hardware Set-up Screen below: Hardware Settings Enable Machine Disable Machine Stop Machine Set External Lamps

25 MKMS Softwares Main Menu ---- MKMS Help About MKMS Save Floor Layout Refres h Exit Edit Defects Shift Set-up Operator Set-up Status Set-up Declare Set-up Extended Shift Set-up Language Efficiency See 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

26 A Main Menu Tour Efficiency Efficiency Screen Mill Efficiency Production Knitter Efficiency Machine Efficiency Style Efficiency

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

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

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

30 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

31 A Main Menu Tour - Status Setup Status Set-up:

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

33 The Knitter/Operator Reacts by Entering a Defect Code

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

35 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

36 The F-1000 alerts the Operator with a Blinking Green Light, to Pre-Doff, or Doff, depending on the F1000s 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 Matrix F-1000 CIRCULAR KNIT

37 Blinking Green Light, alerts Operators to Pre-Doff & Doff PRE-DOFFDOFF ROLL Visual Displays Matrix F-1000

38 140 F-1000 Visual Displays-A Quick Glance at Examples Visual Displays DROP STITCHLOGGED ON

39 140 F-1000 Visual Displays-A Quick Glance at Examples Visual Displays RUN STOPDROP STITCH

40 140 F-1000 Visual Displays-A Quick Glance at Examples Visual Displays NEEDLE RUNF-2000

41 140 F-1000 Visual Displays-A Quick Glance at Examples Visual Displays PRESS OFFMACHINE #

42 140 F-1000 Visual Displays-A Quick Glance at Examples Visual Displays OIL FLUSHSTYLE #

43 140 F-1000 Visual Displays-A Quick Glance at Examples Visual Displays SEAM BYPASSDEFECT LVL

44 140 F-1000 Visual Displays-A Quick Glance at Examples Visual Displays LOG OFFAUTO CAL

45 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

46 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 Style Production

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

48 Reporting – Some Examples : Declaration Report Declaration Report Provides For selected Date, Shift, and Machine, youll 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

49 Reporting – Some Examples : Stop Report Stop Report Provides For selected Date, Shift, and Machine, youll 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

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 X By knitter set number

51 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

52 Some MKMS Actual Reports Knitter Efficiency www. matrixcontrols. net Knitter I.D. Enjoy easy to visualize displays of your Knitters efficiency for the week MKMS Reporting

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

54 MKMS Reports – Knitter Shift Production Summary

55 MKMS Reports – Production Weight Summary (by Style) Shift A

56 MKMS Reports – Knitting Machine Stop Report

57 MKMS Reports – Detailed Auto Downtime Report Detailed Auto Downtime 5/1/08 Shift: All Machine: All Downtime Code: All

58 MKMS Reports – Detailed Fabric Piece Report

59 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

60 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

61 The Numbers Show It, and So Will Yours: Enjoy MKMS ! Production Savings Yearly Savings 5 Year Savings

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

63 Another Look at the 5 System Savings: Enjoy MKMS !

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

65 … 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

66 … 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:

67 Additional MKMS Options to Enjoy: Additional Options: Payroll System Interface Roll Weight Calculation Bar Code Ticket Printing Greige Inspection/Mending Interface Error Sourcing Analysis

68 Additional MKMS Options to Optimize Your Plant The Package Becomes Complete with Automated Production Scheduling and Business and Production Intelligence

69 Automated Production Scheduling Automated Sequencing Integrated Shop Floor Product Scheduling

70 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

71 Automated Production Scheduling 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

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

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

74 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

75 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)

76 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.

77 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!

78 Thank you Very Much! Matrix Controls thanks you for your time and attention. We look forward to working with you. MATRIX = CONTROL Matrix Defined-A rectangular array of numerical data-data Matrix has controlled for 50 years to save you money!

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