MANUFACTURING · OUTDOOR & CONSUMER PRODUCTS · POWERSPORTS

AI Automation for Powersports.

Harmony digitizes paper weld logs and torque sheets, streams weld cells and EOL testers live, keeps VIN genealogy recall-ready, and sequences the line 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

Twelve ways the AI layer earns its keep.

Index · 12 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Paper weld logs and torque sheets, line-side downtime notebooks, build travelers riding the frame, and the daily line plan in Excel, keyed in a day later or never read.

Harmony AI Solution. Captured once at the cell on tablets. The plan becomes a live board the whole floor sees, updated as units move.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Weld parameters live on the cell HMI, torque values inside the tool controller, coat line settings on the panel, EOL results on a standalone PC. Nobody sees them side by side.

Harmony AI Solution. Direct PLC and controller connections to Fanuc, Lincoln, and Panasonic weld cells, Atlas Copco DC torque tools, Nordson and Gema coat lines, and EOL dynos and testers, any brand, via OPC UA or whatever the machine speaks.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. A dyno fail is counted at end of line. The cause is upstream in a weld cell, a torque station, or the coat line, and by the time anyone connects them, a shift of units carries the same flaw into rework.

Harmony AI Solution. EOL fails and final-QC defects captured live with model, option, station, shift, and hour.

U4

RFID + Serial Genealogy

Use case 04 · RFID & SERIALIZATION

Problem. A fastener lot goes suspect. Scoping it means weeks of travelers, torque sheets, and supplier emails, while the lawyers ask for a number nobody has.

Harmony AI Solution. RFID on frames and subassemblies through coat and assembly.

U5

AI Search Across All Data

Use case 05 · AI SEARCH

Problem. "Which frames got that fastener lot?" or "Show EOL fail causes by station this month" means ERP exports, test-PC files, a binder of travelers, and a week of stitching.

Harmony AI Solution. Answered in seconds with sources shown, across the ERP, test data, machine data, and dealer claims. Idle floor TVs become live AI line boards.

U6

AI Production Scheduling

Use case 06 · AI SCHEDULING

Problem. Model mix, option content, color changes on the coat line, and mid-run engineering changes, juggled by hand in Excel every morning.

Harmony AI Solution. AI production scheduling models the plant's own constraints and proposes the sequence: mix, options, colors, and engineering changes in one plan.

U7

Inventory + Shortage Intelligence

Use case 07 · INVENTORY

Problem. Component shortages discovered at the line, fab and assembly counting the same parts differently, cycle counts that eat weekends.

Harmony AI Solution. An AI-maintained true-stock layer for components across fab and assembly. Material-readiness checked before a sequence releases; count drift flagged before it stops the main line.

U8

Yield Optimization

Use case 08 · YIELD OPTIMIZATION

Problem. Steel, tube, and coating usage tallied after the fact against standards nobody believes. Weld and fab scrap lumped into one bucket with no cell attached.

Harmony AI Solution. Live usage against spec for steel, tube, and coating, by line and shift. Weld and fab scrap coded by cell.

U9

Predictive Maintenance

Use case 09 · RESOURCE INTELLIGENCE

Problem. A weld robot or the coat line goes down by surprise, PM windows get bulldozed by the build schedule, work orders vanish into a clipboard.

Harmony AI Solution. Machine memories on welders, presses, and coat lines: history, criticality, live status. Protected PM windows only the owner can move.

U10

Andon + Oee

Use case 10 · ANDON + OEE

Problem. An operator flags a problem by waving someone down. Takt, downtime, and first-pass yield are assembled in Excel days later, argued about, then forgotten.

Harmony AI Solution. Digital andon from any station, routed to the right person with the clock running. Takt, downtime, and first-pass yield live on the boards, same shift.

U11

Supplier Scorecards

Use case 11 · SUPPLIER SCORECARDS

Problem. Incoming defects logged on paper at receiving, argued about at quarterly reviews with no evidence either side trusts.

Harmony AI Solution. Defects captured at receiving and tied to lots. AI ranks suppliers by defect rate and cost impact, with the receiving records and downstream fails attached as evidence.

U12

Back-Office AI Automations

Use case 12 · FULL-SCOPE AI AGENTS · FINANCE, SALES, PROCUREMENT, LOGISTICS

Problem. Dealer invoicing, warranty claims, and registration paperwork eat the office's week. Supervisors rebuild the same morning reports in Excel.

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

Microsoft Dynamics 365PlexEpicorInforDealer management portalsExcelCustom appsLocal servers

MACHINES

Fanuc robotic weld cellsLincoln weld cellsPanasonic weld cellsNordson powder coat linesGema powder coat linesAtlas Copco DC torque toolsEOL dynos and testersRFID 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.

VIN Genealogy Agent

Torque Data Watch

EOL Failure Pattern Agent

Supplier Defect Scorecard

Sequence Readiness Agent

Dealer Warranty Triage

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 powersports floor, and why they happen.

The ERP, weld cells, and warranty claims never share data

The ERP, the weld cells, and the torque controllers each keep their own records and do not connect, and dealer warranty claims never get matched to the build data that.

Build records live on paper

Weld logs, torque sheets, build travelers, and downtime notes are all on paper, and the daily line plan in Excel is out of date by first break.

The VIN exists, but the build history lives in binders

The serial is stamped on the frame, but the weld cell, the torque values on each critical joint, the fastener lots, and the EOL result are all recorded in binders.

Test fails are counted, the cause is never found

The EOL dyno fails a unit and final QC tallies the defect, but the cause sits upstream in a weld cell, a torque station, or the coat line.

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 capture every torque value on the main line?

Yes. Atlas Copco DC torque tools and other smart tools connect at the controller, so every critical joint's tool, program, and torque value streams into the AI layer and lands on the unit's serial. Joints tightened with unmonitored tools get captured at the station until the tooling catches up.

We build vehicles and hard goods on the same campus. Does one layer cover both?

Yes. The same platform runs a welded UTV frame through coat, assembly, and EOL test, and a knife or climbing-hardware line with its own cells and QC gates. Software and hardware agnostic: each line gets its own flow, one AI layer sees both.

Do you replace our ERP?

Additive by default. The AI layer sits on top of what you already run, Dynamics 365, Plex, Epicor, Infor, or anything else, 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.

Trace any VIN to its welds, torques, and test results in seconds, within weeks.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Firearms & Ammunition →Hunting Equipment →Fishing & Marine →Outdoor Living →HVAC Equipment & Components →