MANUFACTURING · PLASTICS, PAPER & MATERIALS · PULP, PAPER & PACKAGING

AI Automation for Pulp, Paper & Packaging.

Harmony digitizes the pen-and-paper run sheets and waste tallies, turns your specs and quotes into one searchable AI layer, streams the presses live, and schedules jobs 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 · 10 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Press run sheets on clipboards, waste tallies on paper, makeready checklists in binders, and a job board living across thousands of Excel tabs. One person knows which tab is current.

Harmony AI Solution. Captured once at the machine on tablets. The job board goes live for the whole floor.

U2

AI Search Across All Data

Use case 02 · AI SEARCH

Problem. Customer specs, SOPs, machine manuals, safety docs, historical orders and pricing scattered across file servers, binders, and inboxes.

Harmony AI Solution. Tens of thousands of documents transformed into one searchable AI layer. "What did we quote them last time?" answered in seconds, with sources shown.

U3

Live Machine Data

Use case 03 · LIVE MACHINE DATA

Problem. Speeds live on the HMI, counts on the run sheet, downtime in a logbook nobody reads. Nobody sees them side by side.

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

U4

In-Line Quality Intelligence

Use case 04 · IN-LINE QUALITY

Problem. Print, registration, and die-cut defects surface at final QC or at the customer. By then the rest of the run carries the same flaw.

Harmony AI Solution. Defects captured at QC as jobs run, with press, substrate lot, shift, and hour attached. ML flags the drift and signals the press upstream before the rest of the run becomes waste.

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Jobs sequenced by hand across presses and converting: due dates, makeready times, and material readiness juggled every morning in the tabs.

Harmony AI Solution. AI-assisted scheduling on the live operational database sequences jobs across presses and converting against due dates, makereadies, and material readiness. The plan proposes.

U6

Yield Optimization

Use case 06 · YIELD OPTIMIZATION

Problem. Trim and waste tallied on paper after the run. A bad setup or a bad lot runs all shift.

Harmony AI Solution. Trim and waste live by machine and by order. A bad run shows in minutes, not at month end.

U7

RFID + Serial Genealogy

Use case 07 · ROLL & LOT GENEALOGY

Problem. Rolls go missing between staging and the press. When a customer calls about a lot, the trail runs through run sheets and tabs.

Harmony AI Solution. RFID roll tracking from staging to the press. Substrate lot to press run to shipment, one-up and one-back in seconds.

U8

Inventory + Shortage Intelligence

Use case 08 · INVENTORY

Problem. Roll stock counted by walking the racks. Inks, plates, and dies found missing at makeready, after the press is already down.

Harmony AI Solution. An AI-maintained true-stock layer for roll stock, inks, plates, and dies. Job-readiness checked before a run is scheduled, not discovered at the machine.

U9

Predictive Maintenance

Use case 09 · RESOURCE INTELLIGENCE

Problem. Presses break down without warning. Downtime reasons are written in a logbook that never gets coded or read.

Harmony AI Solution. Press and corrugator memories with history, criticality, and live status. Downtime coded at the machine and ML-clustered into patterns.

U10

Back-Office AI Automations

Use case 10 · FULL-SCOPE AI AGENTS · FINANCE, SALES, PROCUREMENT, LOGISTICS

Problem. "Where is my order?" answered by walking the floor. Artwork approvals stall in inboxes.

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 / 10

YOUR LIKELY STACK

The systems and machines we meet on your floor.

SYSTEMS

AmtechKiwiplanEFI / ePSCTIQuickBooks-era legacyThousands of Excel tabsCustom appsLocal servers

MACHINES

BobstHeidelbergMark AndyHP IndigoBHS corrugatorsDie-cuttersLaminatorsSlitters

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.

Makeready Waste Watch

Press Speed Anomaly Agent

Job Status Agent

Estimate-vs-Actual Agent

Roll Genealogy Tracer

Artwork Status Agent

PO Inbox Parser

AR + Collections Copilot

Morning Report Writer

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every pulp, paper & packaging floor, and why they happen.

Estimating, scheduling, and the back office never connect

Estimating does not talk to the press, scheduling does not talk to the QuickBooks-era back office, and the same job carries three names in three systems.

Run data is recorded on paper

Press run sheets, waste tallies, makeready checklists, and roll tickets are filled in by hand at the machine.

The schedule lives in thousands of Excel tabs

The schedule, specs, run standards, and pricing history are spread across thousands of Excel tabs.

Waste is counted after the run

Trim and waste are tallied when the run is over, after the rest of the order has picked up the same drift.

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 Amtech, Kiwiplan, or our EFI system?

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. Sometimes we're the layer on top of your MES. Sometimes we are the MES. Software and hardware agnostic.

Can you get live data off our presses and corrugators?

Yes. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, or any other brand, via OPC UA or whatever the machine speaks, streamed into the AI layer in real time. Speeds, counts, waste, downtime, live.

Rolls go missing between staging and the press. Where does RFID fit?

RFID tags and read points go in where the rolls go dark: staging, the press, rewind, returns to stock. Installed as part of the digital transformation, hardware at cost. Every roll answers: where am I right now?

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. Baseline first, then measure. Estimates are labeled as estimates.

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 shows you every run live, so waste gets caught while the job is still on the press.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Plastics & Rubber →Textiles & Apparel →Consumer Packaged Goods →