MANUFACTURING · PACKAGING & PRINTING · CONTRACT PACKAGING

AI Automation for Contract Packaging.

Harmony digitizes line checks and component counts, streams every line live, stages customer components with AI, and meters production straight into invoicing. 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 · 11 use cases

U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Line check sheets, component counts, changeover checklists, and customer paperwork, filled in by hand and keyed into Excel a day later.

Harmony AI Solution. Captured once at the line on tablets. AI flags out-of-range entries the moment they are written, and the customer's paperwork fills itself from the same capture.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Counts live on the HMI, speeds in an operator's head, stops in a logbook nobody reads. The run rate a customer was quoted and the run rate the line actually holds are two different numbers.

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. Weights, date codes, and case counts are checked on paper after the run. A wrong code or a light case surfaces weeks later as a customer rejection and a chargeback on the whole lot.

Harmony AI Solution. Weights, date codes, and case counts watched live as the run happens. ML sees the drift within minutes and signals the line upstream, before a single pallet is wrapped.

U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "Where is that customer's component inventory?" or "What did line 2 run at on the last job for them?" means a walk to the rack, a dig through the portal, and three emails.

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

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Customer runs, component arrivals, line capabilities, changeover order, and ship dates, juggled in Excel every morning and rebuilt every time a truck is late.

Harmony AI Solution. AI production scheduling sequences customer runs against component readiness, line capabilities, and ship dates, and proposes the plan. The scheduler stays in charge and approves.

U6

Inventory + Shortage Intelligence

Use case 06 · COMPONENT READINESS

Problem. The run is scheduled, the crew is assigned, and one customer component is missing. The shortage is discovered at the line, and the shift is spent re-planning instead of packing.

Harmony AI Solution. Every customer component checked against the run before it releases. Shortages flagged a shift ahead, with time to call the customer, re-sequence, and keep the line full.

U7

RFID + Serial Genealogy

Use case 07 · LOT GENEALOGY

Problem. A customer calls about a lot, and the answer lives in a binder of check sheets and a stack of receiving paperwork. Building the trace takes days, and the customer is waiting.

Harmony AI Solution. Every component lot tied to its run, every run tied to its cases, every case tied to the customer shipment. The full genealogy answers in one query, recall-ready.

U8

AI Workflow Automation

Use case 08 · CHANGEOVER ANALYTICS

Problem. Changeovers between customer runs are the biggest hidden cost on the floor, and nobody knows what one actually takes. The checklist is paper and the clock is a guess.

Harmony AI Solution. Every changeover captured from the machines themselves: last good case of one run to first good case of the next.

U9

Labor + Line Productivity

Use case 09 · LABOR + LINE PRODUCTIVITY

Problem. One line runs with eight people, the same job ran last month with six, and nobody can say why. Labor is the co-packer's margin, and it is tracked on a timesheet after the fact.

Harmony AI Solution. Crewing and live run rates on the same screen, by line and by customer job. The plant sees which crews and which setups hold rate, while the shift is still running.

U10

Inventory

Use case 10 · INVENTORY

Problem. Customer-owned components mixed in with house stock, counted on paper, reconciled in Excel. The customer's number, the ERP's number, and the rack never agree.

Harmony AI Solution. An AI-maintained true-stock layer with customer-owned components tracked separately, scan in and scan out.

U11

Back-Office AI Automations

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

Problem. Invoices are built from check sheets and estimates days after the run. Undercounts give margin away quietly, overcounts start a dispute, and month-end is a reconciliation project.

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

NetSuiteSAP Business OneHomegrown ERPsCustomer portalsExcel schedulesCustom appsLocal servers

MACHINES

CartonersFlow wrappersBundlersCase packersSerialization and date-code linesStretch wrappers

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.

Component Readiness Agent

Changeover Watch Agent

Date-Code Drift Watch

Line Rate Watch Agent

Customer Lot Genealogy Agent

Component True-Stock Agent

Customer Report Writer

Invoice Metering Agent

AR + Collections Copilot

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every contract packaging floor, and why they happen.

The ERP, customer portals, and the floor never connect

NetSuite or SAP Business One holds the order, each customer's portal holds its forecast, the schedule lives in Excel, and the line reports on paper.

Lines report on check sheets, so counts arrive late

Line check sheets, component counts, changeover checklists, and customer paperwork are filled in by hand.

Component shortages surface at line setup

A customer ships components short, mislabeled, or late, and nobody knows until the crew is standing at the line.

Weights and date codes are checked after the run

A wrong date code or an underweight case found at final QC, or worse, at the customer's dock, means the entire run is suspect.

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, NetSuite, SAP Business One, or a homegrown system, 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 cartoners, wrappers, and case packers?

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 checkweighers and coders, streamed into the AI layer in real time. Software and hardware agnostic.

Our components are customer-owned. Can you track them separately from our stock?

Yes. Customer-owned components get their own true-stock layer, scanned in at receiving and out at the line, kept apart from house inventory. A run only releases when every component for it is staged, and the customer's count and yours finally agree.

Every customer wants reports and paperwork in their own format. Can the AI handle that?

Yes. Each customer's daily report, lot paperwork, and portal upload is generated in that customer's own format from the same live line data. The office reviews and sends instead of rebuilding it in Excel every morning.

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.

Harmony AI puts components, lines, and customer runs on one live layer, so shortages get caught a shift ahead and the invoice matches what the line actually ran.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Corrugated & Boxes →Folding Cartons →Labels & Flexible Packaging →Rigid Plastics & Closures →Consumer Packaged Goods →