MANUFACTURING · OUTDOOR & CONSUMER PRODUCTS · CAMPING & COOLERS

AI Automation for Camping & Coolers.

Harmony digitizes paper mold logs and leak-test checklists, streams the rotomold ovens live, plans the pre-season build with AI, and traces returns back to lots and lines. 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

Eleven ways the AI layer earns its keep.

Index · 11 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Paper mold logs, oven cycle sheets, trim tally clipboards, leak-test checklists, and a pre-season build plan in Excel that one planner maintains by hand.

Harmony AI Solution. Captured once at the station on tablets, AI flagging out-of-range entries as they are written.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Oven temperatures live on the HMI, rotation ratios in a setup sheet, cycle times on a stopwatch. Nobody sees them next to the defect rates from the same shift.

Harmony AI Solution. Direct PLC connections stream oven temps, rotation ratios, and cycle times in real time, Ferry, Rotoline, or any other brand, via OPC UA or whatever the machine speaks, live next to short shots, warpage, and leak fails from the same hour.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. Short shots, warpage, and leak-test fails surface as units come off the line, after a full shift of cycles carries the same flaw into scrap.

Harmony AI Solution. Every defect captured at the station with its mold, oven, and hour.

U4

RFID + Serial Genealogy

Use case 04 · RFID + SERIALIZATION

Problem. A warranty claim on a cooler arrives and nobody can say which mold, which cycle, which foam batch built it. A part pulled to rework loses its location until someone walks the benches.

Harmony AI Solution. RFID through mold, trim, and assembly, so the location of every part is always known.

U5

AI Search Across All Data

Use case 05 · AI SEARCH

Problem. "Which molds ran that resin batch?" or "What's the leak-fail trend on drinkware line 2?" means a walk to the mold room, a binder, and an Excel export.

Harmony AI Solution. Answered in seconds with the source shown, across the ERP, mold logs, machine data, and returns. Natural-language AI search over everything the plant knows.

U6

AI Production Scheduling

Use case 06 · AI SCHEDULING

Problem. Pre-season builds juggled by hand against forecast and capacity, mixed-line color and size changeovers sequenced from memory, one planner holding the whole year in a spreadsheet.

Harmony AI Solution. AI production scheduling models the builds against forecast and capacity, sequences color and size changeovers across mixed lines, and proposes the plan.

U7

Yield Optimization

Use case 07 · YIELD OPTIMIZATION

Problem. Resin and foam usage per unit is assumed from spec. Trim and flash scrap gets swept, weighed monthly, or never measured at all.

Harmony AI Solution. Actual resin and foam usage per unit against spec, live. Trim and flash scrap by mold and by shift, so an overweight mold or a heavy-handed pour shows in a day, not a quarter.

U8

Inventory + Shortage Intelligence

Use case 08 · INVENTORY

Problem. Resin, foam, hardware, and packaging counts drift between the ERP and the floor. Stockouts surface at assembly, in the middle of the pre-season build.

Harmony AI Solution. An AI-maintained true-stock layer for resin, foam, hardware, and packaging, with build coverage against forecast on one screen.

U9

Predictive Maintenance

Use case 09 · RESOURCE INTELLIGENCE

Problem. A mold runs until it warps parts. An oven fails in the middle of the season peak, when there is no slack to absorb it.

Harmony AI Solution. Mold memories: cycle counts and defect trends per mold, live oven history. ML schedules mold and oven service before failure, in windows the plan can afford.

U10

AI Workflow Automation

Use case 10 · RETURNS INTELLIGENCE

Problem. E-commerce and retail returns pile up as free-text complaints in a spreadsheet nobody mines. A defect trend ships for months before anyone connects it to a line.

Harmony AI Solution. AI parses every return reason, e-comm and retail, and traces it through serialization back to lots and lines.

U11

Back-Office AI Automations

Use case 11 · FULL-SCOPE AI AGENTS · FINANCE, SALES, PROCUREMENT, LOGISTICS

Problem. Retail routing guides read by hand, chargeback disputes assembled from emails and screenshots, the same daily reports rebuilt in Excel every morning.

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.

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YOUR LIKELY STACK

The systems and machines we meet on your floor.

SYSTEMS

NetSuitePlexEpicorExcel-run planningCustom appsLocal servers

MACHINES

Ferry rotomold machinesRotoline rotomold machinesFoam-fill systemsLeak testersJuki sewing linesBrother sewing linesRFID infrastructure

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.

Leak-Test Watch

Mold Cycle Anomaly Agent

Resin Usage Agent

Returns Correlation Agent

Season Coverage Planner

Chargeback Dispute Drafter

Line OEE Watch

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 camping & coolers floor, and why they happen.

Orders, routings, and the build plan never connect

NetSuite holds the orders, Plex or Epicor holds the routings, the build plan lives in Excel, and the ovens and sewing lines are not connected to any of them.

Every check is on paper, so data arrives late

Mold logs, oven cycle sheets, trim tallies, and leak-test checklists are written at the station, then keyed into Excel a day later or never read at all.

The whole year rides on one hand-built plan

Pre-season builds are planned months out against a forecast, in a spreadsheet only one planner truly understands.

Leak fails are counted at end of line

Short shots, warpage, and leak-test fails get tallied at the end of the line, after a full shift of cycles carries the same flaw.

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

Can you get live data off our rotomold machines and sewing lines?

Yes. Direct PLC and sensor connections, Ferry, Rotoline, Allen-Bradley/Rockwell, Siemens, or any other brand, via OPC UA or whatever the machine speaks. Oven temps, rotation ratios, and cycle times stream in real time; sewing lines and leak testers are captured at the station where they have no PLC to offer. Software and hardware agnostic.

Can we trace a warranty claim back to the mold and cycle that built the unit?

That is what serialization is for. RFID through mold, trim, and assembly ties every unit serial to its mold, cycle data, foam batch, and leak-test result. When a claim comes in, the full genealogy is one search away.

Do you replace our ERP?

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.

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.

See every oven, line, and serial in real time, before the season starts.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Firearms & Ammunition →Hunting Equipment →Fishing & Marine →Outdoor Living →Plastics & Rubber →