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 Total Knit Control MKMS Management Software F-1000 MonitorFabric ScanInfrared, High Resolution, Threshold Adjustable, Self Cleaning, Defect Scanning
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, andmore production► Yarn rate monitoring, prevent-ing machine overfeeds► Determining the quality of yarnfrom your suppliers► Happier workers, less turnover
4 www.matrixcontrols.net Take another look: Lower cost Cost per lb.Increase productivity through enhanced scanning, monitoring and control with:Lower costReduce Capital ExpendituresFaster and more timely productionMore accurate resultsMarginOverhead& Cost of CapitalConv. CostsMaterialsKnitting Value Chain
5 www.matrixcontrols.net Train, Learn and Enjoy: ▪ Change: ▪ 50 Years: ▪ Like any tool, in order to maximize production and efficiency,the Matrix Knit Monitoring System requires proper operation. It’snot hard, but Matrix understands that we all are reluctant tochange. But that’s okay, because Matrix also knows that onceyour company and employees realize their work efforts will beeasier, more productive, and more profitable, change will bewelcomed and come fast.▪ 50 Years:▪ Fifty years of Circular Knit Control has given Matrix the tools to teach, train andsuccessfully implement your MKMS system. Our Project Managers, Engineersand staff, will guide your personnel towards profits many companies beforehave enjoyed.▪ Possible Results:▪ Reduction of total defects by 30%, and reduction of inspections from 35% to5%, along with improved production scheduling of fabric rolls, as the millconverts to ‘knit-to-order’. And more…Greige knit yield or working loss – fabric out of spec
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 MKMSpackage. Auto re-route, and the Matrix Dashboard’s immediate data availability andalerts, take manufacturing efficiencies to a new level. Let’s see how MKMS works Lean Manufacturing▪ 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 MKMSpackage. Auto re-route, and the Matrix Dashboard’s immediate data availability andalerts take manufacturing efficiencies to a new level. Let’s see how MKMS works
7 www.matrixcontrols.net How MKMS Works: Fabric Defect Detection: ► Defect mapping capabilities▪ Production stops after programmable number ofdefects are exceeded in roll▪ Scanners are threshold adjustable--you decidewhat 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 andgreige inspection► DOGS or Dirt, Oil and Grease scans recordedand reported to maintenance► Self-cleaning scanner heads, and immediatemachine shut down, if fabric pulls off scannerDetection On:• Jersey • Rib• Rashel • Mesh• Fleece • Terry• Interlock• Spandex• ThermalInstalled On:• Vanguard• Fukuhara• Keum Yong• Mayer• Monarch• Nova• Pai Lung• SsangYung• Terrot
8 MKMS’ Yarn Rate Monitoring: Continuous Yarn Rate Monitoring:► Prevents Overfeeding and Underfeeding—bothlead to poor quality fabric▪ Overfeeding causes a porous fabric that hasloops, which will shrink and use excess yarn▪ Underfeeding produces a heavy, dense andnarrow 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 ofoff quality fabric► Allows you to detect off quality yarn leading torequests 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, andyou 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 TechnicalService ManagerCase study: One 300 machine installation found 60% out of tolerance, and showed a $600,000 overall cost savings.
9 Scanning, Yarn Rate Monitoring and the F-1000 Monitor Controller Introducing the MKMS’ Human-Machine InterfaceScannersF-1000 Monitor/F-1000Yarn Rate Transducers
10 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 AccuracyMKMS impacts each of these areas to increase plant productivity.
11 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 totake action, the total number of repeated point defects is reduced► Providing a Scheduled Maintenance Plan based on accurate counts ofmachine revolutions and knit element life, to reduce the number ofdefects due to improperly timed preventive maintenancetake action, substandard yarn can be flagged within hours andcorrective action taken immediately
12 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 knowledgeof the stop reasons, thereby helping the operator to pinpoint theremedy to the particular stop.► The operator the ability to prioritize the remediation of the stop whenmultiple machines are simultaneously stopped.► Stop-time reporting, which offers feedback to the operator bothgenerally as well as compared to other plant benchmarks to reduce thelength 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 toassist 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 maximumcleaning, reducing time operators spend blowing off knittingelementsMatrix offers additionalmodules to assist yourhouse-keeping efforts:■ Advanced PM (Pre-ventive MaintenanceScheduling■ Machine DiagnosticSoftware-featuresvoice announcingand failure analysis
14 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, andproduction increases tremendously, as do profitsMKMS offers::■ Increased Speed■ Increased Efficiency■ Increased Quality■ Increased Orders■ Increased Profits
15 What you see: www.matrixcontrols.net 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-timeoverview of production status, with immediate drill down capability to an individualmachine/style/operator■ The MKMS Software allows flexibility for custom reporting for additionalproductivity enhancements and options■ The MKMS Software allows the department management team to view overalldowntime occurrences to minimize opportunities lost■ The MKMS Software can integrate downtime and revolution information with theplant payroll and other internal systems, providing improved payroll calculationsand facilitating pay for performance. It does so:Accurately, rapidly, with less man-power, and improves payroll fairnessand accuracyColorMKMS’ RTDISP and AUTODA
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 rapidlyUser Friendly, Point andClick to Color-CodedScreens 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
18 MKMS’s RTDISP www.matrixcontrols.net Current Status of your Entire Knitting Mill Plant Floor
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 thesystem is startedData 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 StartPiece 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 InspectionStyle Data :Notes:Conversion Costs1) Savings related to labor and machine costs have to do with the amount of reduced waste/rags produced. For example, if 5% fewer bad fabric is produced then 5% of the labor and machine costs are saved.2) For Other Conversion costs, these have to do with reduced inspections or mechanics required.Overhead and Cost of Capital1) WIPs are reduced by reducing the amount of time unfinished fabric remains in the plant. If the MKMS can streamline processes so that the time to produce finished fabric is reduced by a single day, then 1 day of WIP capital employed to finance that WIP is reduced. This reduces total capital employed as well as reduces WIP carrying costs, such as, space, interest, materials handling and other costs.2) If the utilization rates are improved by 5% then approximately 5% fewer machines are required to produce the same amount of fabric. These machines could be sold, or contract knitting may be able to be reduced, because the spare capacity may now be available.• 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 FloorIndividual Machine Status IconMachine #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)
21 Current Status Screen www.matrixcontrols.net Click and view the Current Status Screen below:VIEW:► F1000/Operator I.D.► Communication Setting► Current F1000 Status► Configuration Data► Retrieve Data► Set-up HardwareConfigurationRetrieve DataHardware SetUpExit
22 www.matrixcontrols.net Current Configuration Screen Click and view the Current Configuration Screen below:Click Arrow to select F1000View all your settings► Yarn rates► Revolutions► Messaging► Oil/Air Purge► Security
23 www.matrixcontrols.net Retrieve Data Screen Retrieve Input Data Click and view the Retrieve Data Screen below:Retrieve► Shift Data► Piece & Multi-piece► Operator Data► Machine/Operator DataInput DataClick Shift and enter data.
24 www.matrixcontrols.net Hardware Set-up Screen Hardware Settings Click and view the Hardware Set-up Screen below:HardwareSettings► Enable Machine► Disable Machine► Stop Machine► Set External Lamps
25 www.matrixcontrols.net MKMS Software’s Main Menu Send Style See Slide HelpAboutMKMSSaveFloorLayoutRefreshExitEditDefectsShiftSet-upOperatorStatusDeclareExtendedLanguageLog OnLog OffCurrent Shift ►Efficiency ►Machine ►Piece ReportDetail PieceAuto DowntimeDetail Auto DownDowntimeDetail DowntimeDeclarationStops ReportKnitter ShiftStyle ProductionSend StyleSee Slide34AdministrationSee Slide33EfficiencyLog StatusStyle InformationDeclarationsPlant 1Plant 2Plant 3EfficiencySee Slide32
26 www.matrixcontrols.net A Main Menu Tour Efficiency ► Mill Efficiency Efficiency Screen► Mill Efficiency► Production► Knitter Efficiency► Machine Efficiency► Style Efficiency
27 MKMS www.matrixcontrols.net A Main Menu Tour Administration Add/Edit KnittersAdd/Edit MechanicBuild Sets from LayoutAssign Priority From LayoutKnitter Log ON/OFFEdit Knitting MachinesDownload to F1000Add Down TimeRetrieve Shift DataEdit StylesStyle MasterBuild Trial SetsSet Polled From SetsKnitter ReassignmentSecurity LevelsPasswordStyle UpdateMKMS
28 www.matrixcontrols.net A Main Menu Tour Employee Log ON/OFF and Security (Passwords and Levels)Circular Knits Inc.
29 www.matrixcontrols.net A Main Menu Tour Send Style – Fabric Settings Circular Knits Inc.
30 www.matrixcontrols.net 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
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 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 KNITMatrix F-1000
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 KNITMatrix F-1000F1000 Displays-Doff & Pre-Doff
37 Blinking Green Light, alerts Operators to Pre-Doff & Doff Visual DisplaysPRE-DOFFDOFF ROLLMatrix F-1000Matrix F-1000
44 www.matrixcontrols.net www.matrixcontrols.net 140 F-1000 Visual Displays-A Quick Glance at ExamplesVisual DisplaysLOG OFFAUTO CAL
45 F-1000 Visual Displays - Other Typical Daily Displays Top StopBottom StopNeedle StopOperator StopDoff RollFabric DefectPre-DoffCheck Yarn RatesToo Many DefectsPatrolNo Operator AssignedInvalid Style NumberLow Air Pressure
46 Supervision and Analysis Made Easy – F1000 Reports Types of ReportsCurrent ShiftEfficiencyMachinePiece ReportDetail PieceAuto DowntimeDetail Auto-DownDowntimeDetail –DeclarationStops ReportKnitter ShiftStyleProduction
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 www.matrixcontrols.net www.matrixcontrols.net Reporting – Some Examples : Declaration ReportDeclaration 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/rangesAlso Choose the End Type:• Completed Declarations• Canceled Declarations• or Both
49 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 alldates.■ 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 totalexception 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
51 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
52 Some MKMS Actual Reports Knitter Efficiency Knitter I.D. Enjoy easy to visualize displays of your Knitter’s efficiency for the weekMKMS Reportingwww . matrixcontrols . net
53 MKMS Reports - Knitter Efficiency - Another Look Time (Hr)Sum Worked Hours Sum Lost Hours Average of Knitter Eff.
54 MKMS Reports – Knitter Shift Production Summary
55 MKMS Reports – Production Weight Summary (by Style) Shift A
59 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 machines2) Machine Speed Increases - Allows for additional production3) Increased Efficiency - Through Downtime Reduction4) Fabric Defect Detection - Reduced waste, Increased quality, and orders5) Yarn Quality Improvements- Increased efficiency and fabric quality
60 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.Production Scenarios25 Machines-251 Days/YearCIRCULAR40 Machines-251 Days/YearKNIT40 Machines Days/YearCONTROL
61 The Numbers Show It, and So Will Yours: Enjoy MKMS ! Production SavingsYearly Savings5 Year Savings
62 www.matrixcontrols.net …and The Graphics Show It Also: Enjoy MKMS ! U.S. $sIn Seven Years This 25 Machine Mill’s Savings Exceeded 1.2 Million $INCREASING REVENUE OVER YEARS IN U.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, Machines, and 40 Machines Days
65 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
66 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 AvailabilityAdditional Options:
67 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
68 ■ Automated Production Scheduling Additional “MKMS” Options to Optimize Your PlantThe Package Becomes Complete with■ Automated Production Schedulingand■ Business and Production Intelligence
70 www.matrixcontrols.net 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 productionissues► Build a flexible and responsive productionschedule, and actionable status reporting► Control Work-In-Process Inventory
71 www.matrixcontrols.net Automated Production Scheduling Auto Scheduling allows your Company to:► Get the most orders out► Get high priority customer ordersout► Meet the maximum number ofpromise 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 www.matrixcontrols.net Business and Production Intelligence 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 datasources and reports for more detail about whatthe Dashboard shows you▪ Access by product, machine, customer, etc.▪ Access operational or financial data, and drilldown into the lowest levelsNo matter where thedata is, or from what source it originates► Set alerts and notifications to keep you aware of when a metricchanges status► Empower anyone in your organization to monitor and analyzeperformance with ease► Easily customize for any desired type of information delivery
75 www.matrixcontrols.net 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 ofthe solution► You must know when things are going wrong, without having towait 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 timeyou have to react► The Matrix Dashboard will 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 Matrix Controls www.matrixcontrols.net Question: Who wins with MKMS ? Answer: Everyone!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!Matrix ControlsMKMS- Matrix Knit Monitoring System
78 Thank you Very Much!Matrix Controls thanks you for your time and attention. We look forward to working with you.MATRIX=CONTROLMatrix Defined-“A rectangular array of numerical data-data Matrix has controlled for 50 years to save you money!”
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