MANUFACTURING · BUILDING PRODUCTS · BUILDING PRODUCTS

AI Automation for Building Products.

Harmony digitizes the paper log sheets at both ends of the line, streams line speed live, signals the wet end before drift runs, and writes the daily reports with AI. One AI-native operating system over everything: your floor, your machines, and the software you already run. No rip-and-replace.

Start with a pilot ROI Calculators & Tools

THE PROCESS

First a digital transformation. Then an AI transformation.

FIG. 01 · THE TWO ARCS

ARC 1 · DIGITAL

ARC 2 · AI

Data engineering is the work.AI is what it unlocks.

THE PHASED ROLLOUT

Three phases of a digital and AI transformation.

PHASE 01

PHASE 1

Lay the Data Foundation · Digitization

Every pen-and-paper record digitized at the station, every software system connected, and all of the data unified into one live layer. The digital transformation starts here.

PHASE 02

PHASE 2

Production & Operations Scale

Factory operations turn proactive: live sensors and machine data, the AI scheduling board, predictive maintenance before failure.

PHASE 03

PHASE 3

AI-Native Operations

Agents across the floor and the back office act on the live layer: quality signals, reports, copilots. Humans approve.

AI USE CASES

Ten ways the AI layer earns its keep.

Index · 09 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Wet-end log sheets, dry-end log sheets, QC clipboards, scrap tallies. Every morning a supervisor rebuilds the daily production summary in Excel from what the floor already wrote down.

Harmony AI Solution. Captured once at the station on tablets, where the work happens. AI flags out-of-range entries the moment they are written.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Line speed lives on the HMI, zone temps in the historian, kWh on the utility bill, cull counts on a clipboard. Nobody sees them together for the same hour.

Harmony AI Solution. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, any brand, via OPC UA or whatever the machine speaks, streamed in real time next to the cull rate from the same hour.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. Off-spec surfaces at the dry end, or at final QC, or at the customer. On a continuous line the drift has already run for a shift before anyone connects it to a cause.

Harmony AI Solution. Off-spec flagged in real time as product comes off the dry end. ML finds the pattern within minutes and signals the wet end upstream, before the drift runs for a shift.

U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "What did we run the dryer at the last time this SKU held spec all week?" means a walk, a binder, and a historian query someone has to write.

Harmony AI Solution. Answered in seconds with the source cited, across specs, SOPs, test history, the ERP, and the historian. Idle floor TVs become live AI line boards.

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Runs sequenced by hand every morning against raw material levels, dryer capacity, and the order book, with the tradeoffs held in one planner's head.

Harmony AI Solution. AI production scheduling models those constraints and proposes the sequence. The planner stays in charge and approves.

U6

Yield Optimization

Use case 06 · YIELD OPTIMIZATION

Problem. Raw-to-finished yield and trim scrap are tallied after the fact and rolled up at month end. A bad run hides in the average.

Harmony AI Solution. Raw-to-finished yield, trim, and scrap by SKU, live. A drift shows in an hour, not a month, tied to the line conditions that produced it.

U7

Inventory + Shortage Intelligence

Use case 07 · INVENTORY

Problem. Raw levels in one system, finished goods in another, and a physical count that matches neither. Shorts get discovered at the loading dock.

Harmony AI Solution. An AI-maintained true-stock layer reconciles raw and finished goods continuously. Count drift flagged before it becomes a stockout or a short ship.

U8

Predictive Maintenance

Use case 08 · RESOURCE INTELLIGENCE

Problem. A forming line goes down without warning and the plant stops with it. PM windows get skipped when the schedule is tight, and work orders get lost on clipboards.

Harmony AI Solution. Forming and drying line memories with history, criticality, and live status. ML on live machine data schedules service before failure.

U9

Back-Office AI Automations

Use case 09 · FULL-SCOPE AI AGENTS · FINANCE, SALES, PROCUREMENT, LOGISTICS

Problem. A customer or a code official asks for a certificate, and someone reconstructs the lot from log sheets and lab books.

Harmony AI Solution. Full-scope AI agents run the workflows across financial, sales, procurement, and logistics: deductions and AR worked automatically, POs parsed from the inbox, and reports written before the morning meeting.

Scope. Financials, sales, procurement, and logistics automations, in the same platform.

01 / 09

YOUR LIKELY STACK

The systems and machines we meet on your floor.

SYSTEMS

SAPOracleInforPI historiansIgnitionLegacy document archivesExcelCustom appsLocal servers

MACHINES

Continuous forming linesDryersCure ovensWet-end mixingCut and finishing linesOEM and custom-built linesPackaging lines

You might run any of these. Or none of them. Harmony is software and hardware agnostic, and we connect live machine data from any PLC brand and any software or custom app.

AI AGENTS

Agents that watch, flag, and act. Humans decide.

Dry-End Cull Watch

Wet-End Signal Agent

Line Speed Sentinel

COA Generator

Raw Level Reconciler

Trim Scrap Agent

Safety Report Writer

Outage Risk Agent

Morning Report Writer

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every building products floor, and why they happen.

The ERP, the historian, and quality never connect

SAP, Oracle, or Infor holds the orders, PI or Ignition holds the process data, quality lives in a lab book, and scrap on a clipboard.

Both ends of the line are logged on paper

Wet-end and dry-end log sheets, QC clipboards, and scrap tallies are all written by hand.

Wet-end drift is caught at the dry end

On a continuous line, a drift at the wet end does not surface until the dry end, final QC, or the customer.

The setpoints that hold spec live in veterans' heads

These lines are OEM builds with decades of in-house modification.

The back office runs on manual work

POs are typed in from emails, invoices keyed into the ERP, deductions and AR worked from spreadsheets, and reports built by hand before the morning meeting.

THE PILOT

$15–20K. 4–6 weeks. One painful problem.

We pick one specific pain point, send engineers to live in your factory for 4–6 weeks, and solve it. One-time payment, working software by week 3, and no obligation to go further. If you do, you choose the modules that you like.

FIRST CALLSECOND CALLCHOOSE PILOTDATA ACCESS FROM ITON-SITEBUILDTESTROIREVIEW

Start with a pilot →Book a Demo →

QUESTIONS, ANSWERED

Our lines run continuously. Can you connect without stopping them?

Yes. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, or any other brand, via OPC UA or whatever the machine speaks, brought live read-only without interrupting the process. That includes OEM and custom-built lines. Software and hardware agnostic.

We already run PI or Ignition. Do you replace the historian?

No. Additive by default. The AI layer sits on top of what you already run, and when a system deserves to be replaced, we replace it. The historian keeps collecting. Harmony joins its process data to quality, orders, and the ERP, and puts AI search and ML on top of the whole.

Do you replace our ERP?

Sometimes we're the layer on top of your MES. Sometimes we are the MES. Where there is no MES, or a fragmented one, the Harmony platform becomes the factory's MES: station capture, live line boards, quality, genealogy, and scheduling on one AI-native layer. The ERP stays.

How does the AI get our data?

Read-only connections, scheduled exports, or on-prem. Security is reviewed together in scoping. Read-only pilots: every agent proposes, a person approves.

Do you work remotely?

No. We always start a pilot in person and on-site, with forward-deployed engineers on your floor. Very rarely do we do anything remotely.

What does it cost after the pilot?

A per-plant annual platform: unlimited seats, no user fees, hardware at cost. The pilot itself is $15-20K over 4-6 weeks against one painful problem, with working software by week 3.

Harmony AI joins your historian, quality, and orders into one live layer, so the line stops running off-spec for a shift at a time.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Cabinetry, Furniture & Millwork →Windows, Doors & Hardware →HVAC Equipment & Components →Building Materials →