I did what you said and used the alsamixer after running alsaconf and left kmix uninstalled. All worked great until the reboot. Same problem back again, but this time in alsamixer. The difference was when I looked in alsamixer it was not displaying intel like kmix was it was showing device as camera. This was mirrored in YaST. When I had the problem before I could only see 1 sound device, now it is showing me a device called camera. This after a little bit of thinking is a webcam that I havent used before that is still plugged into the dock of the laptop. It would appear that on a reboot it picks this up as a sound card (well it has a mic) and runs with it, shutting out the Intel driver.
I tried a few tests on this, by rebooting with the USB Camera pluggged in and unplugged and it was consistant. I also reinstalled all the kde controls including kmix and kmix works fine as long as the camera is not plugged in and the system is not rebooted.
That leaves me with a working sound system and another little project with the camera.
Thanks for your pointers on this. It led me on the right path although I am a little confused as to why the camera should cause this problem and not even show itself as a device. Only when kmix was uninstalled did I see the device as camera and as another sound device. I can understand why it would lock the master sound and leave the mic slider available.
Still a fully working (almost) Suse
cheers
Dan