About
O.F. Mossberg & Sons is an American firearms manufacturer designing and producing shotguns, rifles, and accessories across its Connecticut headquarters, primary facility in Eagle Pass, Texas, and secondary plant in Torreón, México. The company supplies national sporting goods retailers and wholesale distributors, including Cabela’s, Academy, Sportsman’s Warehouse, RSR Group, and Lipsey’s. Mossberg is the largest pump-action shotgun manufacturer in the world, holding 100+ design and utility patents and standing as the first ISO-9001-certified long-gun manufacturer.
Challenge
Managing high-volume firearms production with fragmented data.
To fulfill demand for over 370,000 firearms per year, O.F. Mossberg & Sons concentrates nearly all of its manufacturing at a dedicated facility in Eagle Pass, Texas. For Chief Information Officer Wes Beighley, keeping operations running smoothly a thousand miles apart from Mossberg’s Connecticut headquarters hinges on real-time insight into the factory floor. As production volumes grew, he saw an opportunity to modernize his team’s production-planning workflows and enable faster, more agile decision-making.
At the time, details from scanned warehouse receipts, sales orders, and assembly-line completions flowed into Microsoft Dynamics 365, Mossberg’s ERP and warehouse management system (WMS), around the clock. To assess daily production readiness across product categories, Production Coordinator Jesus Gomez and his team manually exported this fragmented data into Excel, then built complex formulas to cross-reference BOMs against inventory.
Materials Manager Abraham Rodriguez and his team ran a parallel process every morning.
“Creating a single planning report took three to four hours. By the time you identified a shortage and sent an alert to buyers and work centers, half the day was already gone.”
Abraham Rodriguez · Materials Manager
That meant planners had little time to reallocate materials and adjust line priorities, increasing the risk of costly order shipment delays that could impact Mossberg’s retailer partnerships.
This visibility gap extended to work-in-process (WIP) tracking across the plant’s operations. Reports presented point-in-time snapshots, so Enrique Gomez, IT Business Analyst and Warehouse Manager, and his team walked through each department and back shop to confirm what parts had moved between machining cells, wood shops, and bluing lines. With firearms requiring up to 200 components, manual verification and reconciliation added hours of work across the team.
Plant status updates were largely tracked on whiteboards or shared verbally, turning key operational context into institutional knowledge. This feedback gap left Wes dependent on ad hoc check-ins, limiting his team’s ability to proactively allocate resources, adjust production priorities, and plan long-term capacity.
Wes recognized that establishing real-time operational clarity was key to scaling the business smoothly. Searching for a dedicated operational intelligence solution, he attended industry conferences, talked to vendors, and evaluated several enterprise platforms. However, none offered an intuitive, live view of assembly lines or the rapid time-to-value Mossberg needed to stay ahead of daily production demands.
That’s when he discovered Harmony AI. Its manufacturing expertise, hands-on approach, and integration capabilities gave Wes confidence he’d found the right partner.
“We spent most of our day responding to issues instead of looking for ways to improve. Our team regularly stayed past hours and came in on weekends just to figure out what went wrong and which orders we had to fulfill next.”
Abraham Rodriguez · Materials Manager
Solution
Custom-built platform that delivers real-time production intelligence.
From the start, Wes was impressed by how Harmony AI operated as a hands-on manufacturing partner. Instead of relying on remote discovery calls, Harmony embedded engineers on-site in Eagle Pass, where they spent weeks shadowing Enrique, Jesus, Abraham, and their team as they moved production orders from Dynamics 365 to a finished product. Armed with these first-hand floor observations, Harmony began building structured digital workflows around Mossberg’s existing systems.
“Harmony AI worked side by side with our teams to consolidate data from Dynamics 365 and build the reports we needed,” shares Wes. As Mossberg’s teams tested the outputs and identified opportunities to improve them, Harmony’s engineers turned around changes within a day.
Through this tight feedback loop, Harmony AI deployed a custom operational intelligence platform within just six weeks. The solution layers on top of Mossberg’s infrastructure without requiring a rip-and-replace implementation, paving the way for broader adoption.
Today, Harmony’s platform ingests ERP records and transactional data from Dynamics 365, exploding BOMs and cross-referencing hundreds of components across product categories in seconds. From there, the platform automatically reconciles required parts against live inventory and open purchase orders. This operational view gives planners and coordinators an up-to-date picture of line readiness and material availability.
“With just a single click, we can see which production orders are ready to build, where specific component shortages sit, and which replenishment parts are in transit.”
Enrique Gomez · IT Business Analyst & Warehouse Manager
That instant access replaces daily spreadsheet builds and physical floor walks, cutting planning workflows down to just 30 minutes. As a result, the Eagle Pass team not only eliminates late-night and weekend production work but also reclaims hours of productive time.
This operational clarity accelerates daily decision-making across the plant. Rather than physically hunting down parts, the team can spot emerging production issues, reallocate materials, and proactively adjust assembly lines. For example, when a 3,690-unit shortfall of a component blocked an assembly run, the platform showed which orders it affected and what could be built around it. “We have more visibility into operations, so we can plan each day faster,” notes Jesus.
Multiplied across planners and coordinators, those reclaimed hours compound. In turn, the Eagle Pass team can focus on optimizing shop-floor processes, improving on-time delivery performance, and increasing throughput.
Beyond helping Jesus, Enrique, and Abraham stage assembly lines with confidence, Harmony keeps Wes and broader leadership informed about production status, constraints, and priorities. That way, they can protect delivery dates for key retail partners while making more informed decisions about production capacity and broader operational initiatives.
“Harmony AI consolidated our scattered spreadsheets into one central source of truth, so everyone across our plant is finally looking at the exact same numbers. It helps us identify the root cause of an issue with a click and act on it immediately.”
Enrique Gomez · IT Business Analyst & Warehouse Manager
Results
Mossberg accelerates production planning workflows by 80%.
Harmony AI gave Mossberg a single, real-time source of truth for production planning, eliminating hours of daily spreadsheet work and plant-floor checks. Today, shop-floor teams proactively manage production needs while leadership plans capacity with confidence.
- 120+ labor hours saved weekly
- 80% faster production planning workflows
- 99.4% faster BOM explosion
Mossberg is already expanding its use of Harmony AI, including scenario-planning capabilities and a conversational interface that lets the team ask questions of their production data. Wes expects these inventory and supply-chain improvements to unlock significant financial value as order volumes continue to climb.
“Harmony didn’t just sell us software; they shadowed our team on the plant floor for weeks. In my 35-year career, I’ve never had a vendor show that level of passion, learn our business so closely, and deliver real value in six weeks.”
