MANUFACTURING · FOOD & BEVERAGE · CONSUMER PACKAGED GOODS

AI Automation for Consumer Packaged Goods.

Harmony digitizes the pen-and-paper fill-line logs and changeover checklists, streams fill weights live, sequences SKU changeovers with AI, and works retailer deductions automatically. 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

Twelve ways the AI layer earns its keep.

Index · 12 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Batch sheets, line logbooks, hourly weight checks, and changeover checklists live on clipboards. Schedules and downtime live in Excel, keyed in a day later or never read at all.

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

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Speeds live on the HMI, reject counts in a logbook, scale data on the unit itself. Nobody sees them together, and nobody sees them by line.

Harmony AI Solution. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, any brand, via OPC UA or whatever the machine speaks.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. A light fill or a loose cap surfaces at final QC, or at the retailer. By then a pallet of rework exists and the shift that built it has gone home.

Harmony AI Solution. Fill weights, cap torque, and seal integrity live. ML flags drift on a single head within minutes and signals the upstream station before the rework is built.

U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "What's the pack spec for this retailer?" "Why did line 3 rework spike last week?" means a portal login, three phone calls, and an Excel export.

Harmony AI Solution. Answered in seconds with the source shown, across the ERP, pack specs, machine data, and inboxes. Idle floor TVs become live AI line boards.

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. SKU families, sizes, and fragrances sequenced by hand every morning. One wrong sequence buys an extra washout and a lost hour of line time.

Harmony AI Solution. AI production scheduling sequences SKU families to minimize washouts and size changes, and proposes the plan. The planner stays in charge and approves.

U6

Yield Optimization

Use case 06 · YIELD & GIVEAWAY

Problem. Target weights set fat to stay legal. Giveaway is invisible until the monthly material variance, and by then it is history nobody can assign to a machine.

Harmony AI Solution. Yield and giveaway live, per head, per SKU. A heavy head shows in an hour, not a month.

U7

Back-Office AI Automations

Use case 07 · FULL-SCOPE AI AGENTS · FINANCE, SALES, PROCUREMENT, LOGISTICS

Problem. Deduction codes matched to promos and shortages by hand. Trade promos reconciled a quarter late.

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.

U8

Demand Movers

Use case 08 · DEMAND MOVERS

Problem. A SKU drops and the news arrives in the monthly review, a line on a report with no names attached.

Harmony AI Solution. Spike alerts and SKU-level drops the day they happen, with the exact customers behind each change, so sales calls the account before the quarter ends.

U9

Inventory + Shortage Intelligence

Use case 09 · INVENTORY

Problem. Film, trays, labels, and corrugate run short and the line finds out first. Cycle counts eat weekends and settle nothing.

Harmony AI Solution. An AI-maintained true-stock layer for components: film, trays, labels, and corrugate. A shortage is flagged before the line stops, not after.

U10

RFID + Serial Genealogy

Use case 10 · LOT TRACEABILITY

Problem. A recall question means binders, batch sheets, and a long weekend tracing one lot across compounding, fill, and pack.

Harmony AI Solution. Lot serialization across compounding, fill, and pack. Every case answers for its batch, every batch for its inputs, in seconds.

U11

Co-Packer Visibility

Use case 11 · CO-PACKER VISIBILITY

Problem. Co-packer production arrives as an emailed spreadsheet a week later. Their quality problem becomes your recall.

Harmony AI Solution. Co-packer output, quality, and inventory flow into the same AI layer as your own lines. One view of everything sold under your label.

U12

Predictive Maintenance

Use case 12 · RESOURCE INTELLIGENCE

Problem. A key machine goes down by surprise and the week's schedule goes with it. PM windows get bulldozed for one more run.

Harmony AI Solution. Machine memories with history, criticality, and live status. Protected PM windows only the owner can move.

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YOUR LIKELY STACK

The systems and machines we meet on your floor.

SYSTEMS

SAPMicrosoft Dynamics 365Oracle NetSuiteInforIgnitionRedzone-style productivity toolsExcelCustom appsLocal servers

MACHINES

High-speed wrappers and baggersCase packers and palletizersDouglas cartoners and case packersDelkor case packersIn-line scales and metal detectorsHerma labelersP.E. Labellers

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.

Pack-Weight Watch

Retailer Deduction Copilot

Trade Promo Reconciler

Changeover Sequencer

Component Shortage Agent

Co-Packer Visibility Agent

Demand Spike Alert

PO Inbox Parser

Morning Report Writer

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every consumer packaged goods floor, and why they happen.

The ERP, the lines, and retailer portals never connect

The ERP, the line, the retailer portal, and the Excel schedule each hold a piece of the picture and do not connect.

Every check is on paper, keyed in late or never

Batch sheets, line logbooks, weight checks, quality checks, and changeover checklists live on clipboards, and schedules and downtime live in Excel.

Giveaway goes unmeasured, pack by pack

Target weights are set high to stay legal, so giveaway runs on every line, every SKU, all shift.

Deductions are worked by hand

Retailer deductions land as codes in a portal, and someone matches each one to a promo or a shortage by hand in a spreadsheet.

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

Do you replace our ERP?

Additive by default. The AI layer sits on top of what you already run, SAP, Dynamics 365, NetSuite, Infor, Ignition, and when a system deserves to be replaced, we replace it. Sometimes we're the layer on top of your MES. Sometimes we are the MES.

Can you get live data off our lines and packaging machines?

Yes. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, or any other brand, via OPC UA or whatever the machine speaks, plus in-line scales and testers, streamed into the AI layer in real time. Software and hardware agnostic.

Can the AI really work our retailer deductions?

Yes. An AI deduction agent reads each deduction, classifies it, matches it to promos and shortages, and drafts the dispute. Every agent proposes. A person approves. Thousands of hours recovered per year, per client, is the pattern.

Half our volume runs at co-packers. Does that break the model?

No. Co-packer output, quality, and inventory feed the same AI layer as your own lines, by scheduled export, portal, or direct connection. One view of everything sold under your label.

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.

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.

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.

Catch fill drift in minutes and stop rework before it is built, within weeks.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Bakery & Snacks →Meat & Poultry →Dairy →Pulp, Paper & Packaging →