Harmony AI
MANUFACTURING · PACKAGING & PRINTING · LABELS & FLEXIBLE PACKAGING

AI Automation for Labels & Flexible Packaging.

Harmony digitizes press run sheets and matrix tallies, streams every press live, sequences changeovers with AI, and answers any spec or quote question in seconds. One AI-native operating system over everything: your floor, your machines, and the software you already run. No rip-and-replace.

Chattanooga Labeling Systems, decorating glass and packaging since 1991, runs with Harmony AI on the floor.

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THE PROCESS

First a digital transformation. Then an AI transformation.

FIG. 01 · THE TWO ARCSARC 1 · THE DIGITAL TRANSFORMATIONARC 2 · THE AI TRANSFORMATIONCLIPBOARDS & PAPEREXCEL & TRACKERSERP & SOFTWAREPLCS & MACHINESDIGITIZECONNECTUNIFYFORWARD-DEPLOYED ENGINEERSON YOUR FLOOR · IN PERSON · IN WEEKSHARMONY AI PLATFORMONE LIVE DATA LAYERERP · PLCS · SENSORS · SCALESQUALITY · INBOXES · DOCS · SPREADSHEETSNO MES? THIS BECOMES THE MESAI SEARCH · SOURCES CITEDAI AGENTS · HUMANS APPROVEAI PRODUCTION SCHEDULINGBACK-OFFICE AUTOMATIONS
ARC 1 · DIGITALTHE DIGITAL TRANSFORMATIONCLIPBOARDSEXCELERP + SOFTWAREMACHINES (PLCS)DIGITIZE · CONNECT · UNIFYONE LIVE DATA LAYEREVERY RECORD, SYSTEM, AND MACHINEBUILT ON-SITE, IN PERSON
ARC 2 · AITHE AI TRANSFORMATIONONE LIVE DATA LAYERTHE FOUNDATIONAI SEARCHANSWERS WITH SOURCES CITEDAI AGENTSPROPOSE · A PERSON APPROVESAI PRODUCTION SCHEDULINGTHE PLAN PROPOSES, PLANNER APPROVESBACK-OFFICE AI AUTOMATIONSFINANCE · SALES · PROCUREMENT · LOGISTICSAI ON TOP OF THE FOUNDATION
Data engineering is the work.AI is what it unlocks.
THE PHASED ROLLOUT

Three phases of a digital and AI transformation.

PHASE 01PAPEREXCELCAPTUREDONE LIVEDATALAYEREVERY PAPER POINT DIGITIZED · MACHINES CONNECTED
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 02SENSORS LIVEAI SCHEDULE BOARDPM BEFORE FAILUREPROACTIVE OPERATIONS AT SCALE
PHASE 2

Production & Operations Scale

Factory operations turn proactive: live sensors and machine data, the AI scheduling board, predictive maintenance before failure.

PHASE 03LIVE DATALAYERAGENTAGENTAGENTHUMANS APPROVEAGENTS ACT ON THE LIVE LAYER
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.

PAPERSTATION TABLETLIVECAPTURED ONCE · SAME SHIFT
U1

Paperwork Digitization

Use case 01 · PEN, PAPER & EXCEL

Problem. Press run sheets, matrix waste tallies, and changeover checklists are filled in by hand at the press, then keyed into Excel a day later.

Harmony AI Solution. Captured once at the press on tablets. AI flags out-of-range entries the moment they are written, and the numbers are on the board the same shift.

ANY PLCLIVEONE SCREENSTREAMED IN REAL TIME
U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Press speed lives on the HMI, footage on a counter, stops in the operator's memory. Nobody sees them next to the job that was running.

Harmony AI Solution. Direct PLC connections stream speeds, footage, and stops in real time, Mark Andy, Nilpeter, HP Indigo, or any other brand, via OPC UA or whatever the machine speaks, next to the job and crew from the same hour.

01020304DEFECT FOUNDSIGNAL SENT UPSTREAM, SAME SHIFTFIXED AT THE START OF THE LINE
U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. Registration walks and color drifts mid-run, and it surfaces at inspection after the roll is wound. The whole roll is already waste.

Harmony AI Solution. Registration and color readings are captured as the roll runs, tied to job, press, and hour.

ASK ANYTHINGAI SEARCHALL SYSTEMSANSWER + SOURCES CITEDSECONDS, NOT PHONE CALLS
U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "What are the specs for this customer's label?" or "What did we quote them last time?" means a walk to the shared drive, a dig through old emails, and a call to whoever ran it last.

Harmony AI Solution. Answered in seconds with the source shown, across the ERP, spec files, run history, and inboxes. Idle floor TVs become live AI press boards.

THE PLAN PROPOSESPLANNER APPROVESCONSTRAINTS MODELED, NEVER GUESSED
U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Jobs are sequenced across presses by hand every morning, juggling due dates, plate and substrate changeovers, and whether the material has even arrived.

Harmony AI Solution. AI production scheduling sequences jobs across presses against due dates, changeover cost, and material readiness, and proposes the plan.

MATERIAL INLOSSLIVE, BY LOTA BAD LOT SHOWS IN AN HOUR
U6

Yield Optimization

Use case 06 · WASTE WATCH

Problem. Matrix and setup waste is tallied on paper after the run. A press that wastes more than its twin runs that way for a quarter before anyone can prove it.

Harmony AI Solution. Waste tracked live by job, press, and crew. The outlier shows the same shift it happens, next to the job that caused it.

STATIONREPAIRRFID TAGLAST KNOWN LOCATION · GENEALOGY
U7

RFID + Serial Genealogy

Use case 07 · ROLL GENEALOGY

Problem. A customer complaint means digging through run sheets to guess which substrate lot fed which press run and which finished rolls shipped where.

Harmony AI Solution. Substrate lot to press run to finished roll to customer, linked at every scan.

CAPTUREDUNIFIEDACTED ONONE LIVE LAYER, HUMANS DECIDE
U8

AI Workflow Automation

Use case 08 · CHANGEOVER ANALYTICS

Problem. Plate and substrate changes are timed by nobody. The best sequence lives in one crew's habits and leaves when they do.

Harmony AI Solution. Every changeover measured live from the machine data. ML finds the patterns behind the fastest ones, and the method that wins becomes the standard, written down.

AI AGENTEVENT INACTION OUTWATCHESALERTSHUMANS APPROVE EVERY ACTION
U9

Estimating Vs Actuals

Use case 09 · ESTIMATING VS ACTUALS

Problem. Jobs are quoted on standards nobody has checked in years. Which jobs actually made money is a debate, not a report.

Harmony AI Solution. Estimated speed, waste, and hours sit next to actuals from the press, job by job. The standards get corrected by the floor's own data, and the next quote starts from the truth.

SYSTEM40FLOOR12TRUESTOCKAI AGENTPOSUPPLIERPO DRAFTED AUTOMATICALLY · A PERSON APPROVES
U10

Inventory + Shortage Intelligence

Use case 10 · INVENTORY

Problem. The system shows substrate rolls that were consumed weeks ago, plates that cannot be found, and ink and core stockouts discovered at the press.

Harmony AI Solution. An AI-maintained true-stock layer for substrates, inks, plates, and cores. Material-readiness before a job releases; count drift flagged before tomorrow's press sits idle.

SENSEDSCOREDSOLVEDAGENTS PROPOSE, PEOPLE APPROVE
U11

Artwork + Approvals

Use case 11 · ARTWORK & APPROVALS

Problem. Artwork sits in a customer's inbox waiting on approval while its press slot creeps closer. The miss is discovered when the job is due on press.

Harmony AI Solution. An AI agent tracks every job's artwork and approval status against its press date and flags the ones that will miss, days early, while there is still time to chase the approval or move the slot.

INVOICESPOSREPORTSAI AGENT, WORKINGAPPROVEDFINANCE · SALES · PROCUREMENT · LOGISTICS
U12

Back-Office AI Automations

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

Problem. Office staff rebuild the same daily reports in Excel, invoices lag the shipments they bill, and AR follow-up eats afternoons.

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
Label TraxxCERMEFI RadiusHomegrown ERPsShared-drive spec filesExcelCustom appsLocal servers
MACHINES
Mark Andy flexo pressesNilpeter flexo pressesHP Indigo digital pressesLaminatorsSlitter-rewinders

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.

Every agent proposes. A person approves. That line never moves.

AI AGENTS

Agents that watch, flag, and act. Humans decide.

Matrix Waste Watch
Registration Drift Agent
Changeover Timer Agent
Roll Genealogy Agent
Substrate Readiness Agent
Artwork Deadline Agent
Invoice Draft Agent
AR + Collections Copilot
Daily Report Writer
Custom Agents, built for your floor and back office
THE PATTERN WE SEE

The problems we see on every labels & flexible packaging floor, and why they happen.

The ERP, the pressroom, and spec files never connect

Label Traxx or CERM holds the job, the press runs on its own controls, and the customer's specs live in a shared drive and old emails.

Run data lives on paper run sheets

Press run sheets, matrix waste tallies, and changeover checklists are filled in by hand at the press.

Changeovers are run from memory

Plate changes, substrate swaps, and color washups follow whatever sequence the operator learned.

Drift is caught at the rewinder, too late

Registration walks and color drifts mid-run, and the numbers surface at inspection after the roll is wound.

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.

ON-SITE, IN PERSON · SOFTWARE + HARDWARE AGNOSTIC · READ-ONLY PILOTS · US-HOSTED OR ON-PREM · HUMANS APPROVE EVERY ACTION

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
QUESTIONS, ANSWERED
Do you replace Label Traxx, CERM, or our homegrown 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: press capture, live boards, waste, genealogy, and scheduling on one AI-native layer.

Can you get live data off our Mark Andy, Nilpeter, and HP Indigo presses?

Yes. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, or any other brand, via OPC UA or whatever the machine speaks, on presses, laminators, and slitter-rewinders, streamed into the AI layer in real time. Software and hardware agnostic.

Our customers ask for lot traceability. Can you give us one-up and one-back?

Yes. Roll scans at each step link substrate lot to press run to finished roll to customer. When a complaint or recall comes, the rolls affected are identified in seconds instead of a day of digging through run sheets.

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.

Harmony AI puts the presses, the specs, and the schedule on one live layer, so drift gets caught at the press instead of at the rewinder.