KnitForcePower to

management

Knit Monitoring & Yarn Control System

Ventura Automation Services Inc

Loop Length/Production DAQ System Server RS-485 to RS-232 Converters KnitForce Software

Components of KnitForce

Loop Length/Production DAQ System (LLM)

1. LLM would be fixed on each Knitting Machine2. Each LLM would have connections as follows

1. Encoder that is fixed on each Yarn Storage Feeder2. In case you require to monitor 2 belts, then 2 counters & Encoders3. Proximity Sensors –

1. To count rotations 2. Measure RPM3. Identify RUN/Stop condition

4. Automatic Inputs from knitting machine1. Yarn Stoppage (From Knitting Machine2. Broken Needle (From needle detector in Knitting Machine)3. Doff Stop (From Relay output on Knitting Machine)4. Press Off /Set Off (From knitting Machine (Single Jersey Only)

5. Automatic Machine Stoppages1. Over Speed2. Incorrect yarn feed beyond tolerance level

Components of KnitForce

The Flow Setting the machine metrics to the meter manually before installation After installation, the meter continues to display the loop length value of

the knitted fabric per CAM rotation As the meter has an eye on this loop length value, it will turn off the

machine when this value deviates from the standard one After the appropriate knitting machine changes are made, the machine

can be turned on again manually The meter constantly monitors the needle break and yarn cut in the

machine and will communicate this detail to the ERP. The number of revolution of the feeder encoder per CAM rotation and the

number of rotations of CAM per minute gets calculated in the meter and can be checked at any point of time by pressing appropriate keys.

Product Specifications

Loop Length Meter and Data Acquisition System Micro-controller based System Loop Length measurement is based on proximity sensor (sensing the CAM rotation)

and rotary encoder (sensing feeder rotation) RS-485 Communications to Server Measures the loop length & sends the information to server Keypad interface to make appropriate setting to the meter in case of varied work

flow Reasons for Stoppage can also be identified through keypad interface A SPST Relay is used to turn off the knitting machine when a varied loop length is

identified Lamp indication for yarn cut and needle break conditions Inbuilt memory backup of information in case of power failure Seamless half duplex communication to server SMPS based power supply

Server A separate server is required to store

following Production Information Fabric Inspection & Defect Analysis System

(FIDAS) SMS Alerts Shed Defect Alert Display Shed Production & Efficiency Display

Components of KnitForce

KnitForce Software Automatic Feed from ERP & Inhouse

Software Customized Product Development for Valli

Textiles Integration with FIDAS Integration with Shed Display Systems Every day Production SMS alerts Developed in VB. Net & MS SQL backend

Components of KnitForce

■ KnitForce Software Color Coding provides the management team a real-time

overview of production status, with immediate drill down capability to an individual

machine/style/operator

■ The KnitForce Software allows flexibility for custom reporting for additional

productivity enhancements and options

■ The KnitForce Software allows the department management team to view overall

downtime occurrences to minimize opportunities lost

■ The KnitForce Software can integrate downtime and revolution information with other internal systems and facilitating pay for performance

KnitForce Benefits

► 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

Utilizing this yarn rate control system even minimal % of adjustment would lead to greater profits on yarn consumption.

Benefits of Yarn Rate Control

Realtime Display System – On

Computer

Production Monitoring InformationMachine#Current StatusShift ProductionShiftwise UtilizationShift Wise EfficiencyYarn Rate Consumption (Loop Length)Style Wise ProductionEmployee Production, Utilization, EfficiencyStoppage Report

REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARDALL

MACHINES

STYLEPLANT INFO

QUALITYPRODUCTI

ON REPORTS

ALL KNITTERS

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

YARN HIGH

SJ145

Shed No/MC

Eff%

TotalProd

1/23 87.45

21225

2/17 89.00

12567

3/10 97.87

5665

4 84.43

5

6

7

8

9

10

11

12

13

14

15

REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARDALL

MACHINES

STYLEPLANT INFO

QUALITYPRODUCT

ION REPORTS

ALL KNITTERS

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

KUMARAVEL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

DINESH

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

MANIVANNA

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

SENTHIL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

KUMARAVEL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

DINESH

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

MANIVANNA

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

SENTHIL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

KUMARAVEL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

DINESH

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

MANIVANNA

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

SENTHIL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

KUMARAVEL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

DINESH

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

MANIVANNA

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

SENTHIL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

KUMARAVEL

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

DINESH

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

MANIVANNA

UTL 87.45%

PROD 2145 KGS

EFF 97.35%

SENTHIL

Shed /Kniter

Eff%

TotalProd

1/Kumarvel

87.45

1225

1/Sundar 89.00

2567

3 97.87

5665

4 84.43

5

6

7

8

9

10

11

12

13

14

15

REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARDALL

MACHINES

PLANT INFO

QUALITYPRODUCT

ION REPORTS

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

ALL KNITTER

S

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

PLAN10200

PROD 7845 KGS

QUALITY97.35%

Ab-1549

STYLEStyle/WorkOrder#

Plan Actual

1234/500 2456 1225

2323/345 3445 2567

REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARD

ALL MACHINES STYLE PLANT

INFO

PRODUCTION

REPORTS

ALL KNITTERS

To be Decided

REAL TIME PRODUCTION MONITORING SYSTEM - DASHBOARDALL

MACHINES

STYLE PLANT INFO

QUALITYALL

KNITTERS REPORTS

To be Decided

3rd Party Energy Monitoring System can be integrated with existing Software

Meanwhile we shall arrange for a quote form our associate partner for energy monitoring system

3rd Party Energy Monitoring Integration

Types of Possible ReportsCurrent Shift

Efficiency

Machine

Detail Piece

Auto Downtime

Detail Auto-Downtime

Downtime

Detail – DowntimeDeclaration

Stops Report

Knitter Shift

Style Production