MANUFACTURING · PACKAGING & PRINTING · PRINTING & DECORATING

AI Automation for Printing & Decorating.

Harmony digitizes run sheets and reject tallies, streams lehrs and cure ovens live, tracks fixtures and screens, and ties every reject to its cause. 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. Run sheets on clipboards, reject tallies on scrap paper, lehr logbooks by the oven, fixture cards in a drawer, keyed into Excel a day later or never at all.

Harmony AI Solution. Captured once at the line on tablets. AI document processing reads the handwritten history already in the drawers.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Zone temps live on the lehr controller, line speed on the HMI, piece counts on a hand tally. Nobody sees them next to the reject numbers from the same hour.

Harmony AI Solution. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, any brand, via OPC UA or whatever the machine speaks, stream temps, line speed, and counts in real time.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. Registration, adhesion, and color rejects are tallied at the end of the lehr. By then, hours of ware carry the same flaw, and the cause is a guess.

Harmony AI Solution. Every reject captured with its cause as ware exits: job, fixture, screen, lehr zone, hour. ML shows the pattern within minutes and signals the press before the next rack loads.

U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "What did this customer's last run reject at?" "Which fixture ran that job?" means pulling run sheets from a drawer, three phone calls, and an afternoon.

Harmony AI Solution. Answered in seconds with the source shown, across the ERP, run sheets, machine data, and inboxes. Natural-language questions, cited answers.

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Jobs sequenced by hand across lines against due dates, screen availability, fixture availability, and cure capacity, redone every time a rush order lands.

Harmony AI Solution. AI production scheduling models the constraints and proposes the sequence across every line. The planner stays in charge and approves.

U6

RFID + Serial Genealogy

Use case 06 · TOOLING LOCATOR

Problem. Fixtures and screens live on racks, in drawers, and wherever the last job left them. The press waits while someone searches.

Harmony AI Solution. Every fixture and screen tracked with scan in/out and location. Every fixture answers: where am I right now?

U7

Ware Genealogy

Use case 07 · WARE GENEALOGY

Problem. Tying a ware lot to a decoration run to a shipment means pulling paper from receiving, the floor, and the office, and hoping the dates line up.

Harmony AI Solution. One-up, one-back genealogy: ware lot to decoration run to shipment, linked automatically, answered in seconds when a customer calls.

U8

AI Workflow Automation

Use case 08 · CHANGEOVER ANALYTICS

Problem. Changeover time disappears into the shift. Nobody knows which setups run long, on which jobs, or why.

Harmony AI Solution. Setup start and stop captured at the line. Analytics by job, fixture, and crew surface the long setups with their causes, so the fixes are specific.

U9

Estimating Vs Actuals

Use case 09 · ESTIMATING VS ACTUALS

Problem. Estimates lean on standard speeds and reject rates nobody has checked in years. The jobs that lose money look fine until the year-end close.

Harmony AI Solution. Actual reject rates and line speeds by job type fed back to estimating. The quote reflects what the floor really runs, before it goes out.

U10

Inventory + Shortage Intelligence

Use case 10 · INVENTORY

Problem. Ware, inks, and screens counted on paper. Shortages are discovered at setup, and the run waits on a rush order of ware.

Harmony AI Solution. An AI-maintained true-stock layer for ware, inks, and screens. Material readiness checked before a job releases; count drift flagged before it stops a line.

U11

Back-Office AI Automations

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

Problem. Lehr and cure profiles logged by hand in a logbook. A customer audit means reconstructing runs from paper, days of it.

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

Homegrown ERPsQuickBooks-era systemsExcel run sheetsEFICustom appsLocal servers

MACHINES

Screen printing linesDecorating lehrsPad printersUV cure ovensFixtures and tooling

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.

Fixture + Screen Locator

Lehr Zone Drift Watch

Registration Reject Cluster Agent

Ware Genealogy Agent

Changeover Setup Agent

Ink + Ware True-Stock Agent

Order Status Responder

Invoicing + AR Copilot

Daily Report Writer

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every printing & decorating floor, and why they happen.

The ERP, run sheets, and lehr logs never connect

The homegrown ERP holds the orders, a QuickBooks-era system holds the invoices, EFI holds the estimates, and Excel holds the run sheets.

The floor is recorded on paper

Run sheets, reject tallies, lehr logbooks, and fixture cards are filled in by hand at the line.

Rejects are counted at the end of the lehr

By the time registration, adhesion, and color rejects are tallied, hours of ware carry the same flaw.

Fixtures and screens are tracked on cards and in heads

The press sits idle while someone walks the racks looking for the fixture that ran the job last time.

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, homegrown ERP, QuickBooks-era systems, EFI, 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 lehrs, cure ovens, and print lines?

Yes. Direct PLC and sensor connections, Allen-Bradley/Rockwell, Siemens, Omron, Mitsubishi, or any other brand, via OPC UA or whatever the machine speaks. Zone temps, line speed, and piece counts streamed into the AI layer in real time. Software and hardware agnostic.

Our customers audit decoration runs. Can the platform produce cure records?

Yes. Lehr and cure profile records are generated from the live machine data and tied to the job and ware lot, so the record exists the moment the run does. Baseline first, then measure. Estimates are labeled as estimates.

Our fixtures and screens are the real bottleneck. Where does tracking fit?

Scan points and tags go in where tooling goes dark: racks, presses, screen storage, rework. Installed as part of the digital transformation, hardware agnostic, at cost. Every fixture answers: where am I right now?

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. Data engineering is the work. AI is what it unlocks.

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 run sheets, lehr data, and reject patterns on one live layer, so the cause gets fixed while the run is still on the line.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Corrugated & Boxes →Folding Cartons →Labels & Flexible Packaging →Glass & Container Manufacturing →