AI Automation for Folding Cartons.

Problem. Speed lives on the HMI, sheet counts on a clipboard, and stops in the operator's memory. Nobody sees them next to the schedule or the waste numbers.

Harmony AI Solution. Direct PLC and sensor connections, Heidelberg, Koenig & Bauer, Bobst, or any other brand, via OPC UA or whatever the machine speaks.

Problem. Color drift, misregistration, and crack-and-peel at the folder-gluer are found at final inspection or by the customer. By then thousands of cartons carry the same flaw.

Harmony AI Solution. Every defect captured at the station with its cause: job, machine, board lot, shift, hour.

Problem. "What did we run this carton at last time?" or "Which jobs used that board lot?" means digging through the ERP, a run-history binder, and somebody's inbox.

Harmony AI Solution. Answered in seconds with the source shown, across the ERP, run history, spec files, and inboxes. Natural-language AI search over everything the plant has ever recorded.

Problem. Jobs sequenced across press, die cut, and gluing by hand every morning, against due dates, makereadies, and whichever hot job just landed. The Excel schedule is stale by the first changeover.

Harmony AI Solution. AI production scheduling models the scheduler's own logic, sequences jobs to protect due dates and minimize makereadies, and proposes the plan.

Problem. Makeready waste is counted after the fact and buried in a monthly scrap number. Which jobs, machines, and crews burn the most board is anyone's guess.

Harmony AI Solution. Setup waste measured live, by job, machine, and crew. ML finds the patterns: the job families, board grades, and changeover sequences that quietly eat the margin.

Problem. A board complaint or a customer hold means days of digging through mill certs, run sheets, and shipping paperwork to find what else that lot touched.

Harmony AI Solution. Board lot to press run to die cut to gluer to shipment, linked automatically. One question answers what a lot fed and where every carton went, one-up and one-back.

Problem. Plates, dies, and stripping tools live on racks nobody indexes. The press sits ready while someone walks the tool room looking for the die.

Harmony AI Solution. Every plate and die tracked by location, condition, and last run. The tooling for tomorrow's jobs is staged before the shift starts.

Problem. Estimates run on standard speeds and waste allowances nobody believes. The jobs that lose money keep getting quoted the same way.

Harmony AI Solution. Actual run speeds, makeready times, and waste flow back from the floor to the estimate. The next quote is built on what the plant really does.

Problem. Board shows in the system that was consumed weeks ago, ink and coating stockouts get discovered mid-run, and nobody trusts the die inventory.

Harmony AI Solution. An AI-maintained true-stock layer for board, ink, coatings, and dies. Material-readiness before a job releases; count drift flagged before it stops a press.

Problem. OEE is a monthly number in a slide deck. Short stops on the gluer and slow-running jobs on the press vanish into the average.

Harmony AI Solution. OEE computed live per machine from the PLC data. ML clusters the stops by cause, so the biggest repeat offender is a named problem, not a feeling.

Problem. CSRs chase order and artwork status across systems and inboxes, invoicing lags the shipment, AR cleanups eat afternoons, and supervisors rebuild the same daily 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.