MANUFACTURING · PACKAGING & PRINTING · RIGID PLASTICS & CLOSURES

AI Automation for Rigid Plastics & Closures.

Harmony digitizes operator run reports, streams presses and closure lines live, balances cavities with ML, and quotes from actual cycles and scrap. 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. Operator run reports, scrap counts, and changeover checklists are filled in by hand at the press and keyed into Excel a day later. Hours a week spent retyping what the floor already wrote down.

Harmony AI Solution. Captured once at the press on tablets. AI flags out-of-range entries the moment they are written, and the shift's numbers exist before the shift ends.

U2

Live Machine Data

Use case 02 · LIVE MACHINE DATA

Problem. Cycle time lives on the HMI, cavitation on the setup sheet, output on a clipboard. Nobody sees them next to the scrap from the same hour.

Harmony AI Solution. Direct PLC connections stream cycles, active cavities, output, and downtime in real time, Husky, Netstal, or any other brand, via OPC UA or whatever the machine speaks.

U3

In-Line Quality Intelligence

Use case 03 · IN-LINE QUALITY

Problem. Short shots, flash, and dimensional rejects are found at inspection, hours after the cycle drifted. A full run carries the same flaw into regrind.

Harmony AI Solution. Every reject captured live with its cause: press, mold, cavity, resin lot, shift, hour.

U4

AI Search Across All Data

Use case 04 · AI SEARCH

Problem. "Scrap by resin lot this month?" "Margin by mold?" means three exports from two systems and an afternoon in Excel.

Harmony AI Solution. Natural-language AI search answers in seconds with the source shown, across the ERP, machine data, and quality capture. Idle floor TVs become live AI press boards.

U5

AI Production Scheduling

Use case 05 · AI SCHEDULING

Problem. Jobs sequenced across presses by hand every morning: due dates against color changes, resin compatibility, and which mold fits which press.

Harmony AI Solution. AI production scheduling sequences jobs to minimize color and resin changes and hit due dates. The plan proposes.

U6

Yield Optimization

Use case 06 · CAVITY BALANCE

Problem. A blocked or worn cavity drags yield for weeks, because output is counted at the mold, not the cavity.

Harmony AI Solution. Per-cavity output and reject rates, live. A cavity that drifts shows up within the hour, and the yield math finally matches the floor.

U7

RFID + Serial Genealogy

Use case 07 · RESIN GENEALOGY

Problem. A customer complaint means digging through gaylord tags, dryer logs, and pack-out records to guess which lot ran when.

Harmony AI Solution. Every resin lot scanned from receipt through dryer and press to finished carton. One-up, one-back traceability in seconds, not days.

U8

AI Workflow Automation

Use case 08 · CHANGEOVER ANALYTICS

Problem. Changeovers eat hours nobody measures. The gap from last good part to first good part lives in nobody's report.

Harmony AI Solution. Every mold and color change clocked automatically from press data. Long changeovers surface with their cause, and the schedule learns from actuals.

U9

Quote-To-Cost

Use case 09 · QUOTE-TO-COST

Problem. Quoting assumes standard cycles and standard scrap. Which jobs actually make money is a debate, not a report.

Harmony AI Solution. Actual cycles, scrap, and changeover time flow back into quoting. Margin by mold and by job, live, so the next quote is priced on what the press really does.

U10

Inventory + Shortage Intelligence

Use case 10 · INVENTORY

Problem. Phantom resin inventory, colorant stockouts discovered at the blender, carton shortages found at pack-out.

Harmony AI Solution. An AI-maintained true-stock layer for resin, colorant, and cartons. Material-readiness checked before a job releases; count drift flagged before it stops a press.

U11

Predictive Maintenance

Use case 11 · MOLD MAINTENANCE

Problem. Tool service happens on breakdown or on a guess. A tired mold runs until flash and short shots force it out mid-run.

Harmony AI Solution. Shot counts and defect trends per mold, live. Predictive maintenance models schedule tool service before failure, in a window the schedule can afford.

U12

Back-Office AI Automations

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

Problem. POs retyped from PDFs, invoices built by hand, AR worked from an aging report, supervisors rebuilding 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.

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YOUR LIKELY STACK

The systems and machines we meet on your floor.

SYSTEMS

IQMS / DELMIAworksPlexEpicorHomegrown ERPsQuality spreadsheetsExcelCustom appsLocal servers

MACHINES

Husky injection systemsNetstal injection systemsBlow moldersCompression closure linesIML robotsConair dryers and auxiliaries

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.

Cavity Drift Watch

Resin Lot Tracer

Changeover Clock Agent

Mold Service Scheduler

Material Readiness Agent

Quote-to-Cost Agent

PO Inbox Parser

Invoice + AR Copilot

Daily Report Writer

Custom Agents, built for your floor and back office

THE PATTERN WE SEE

The problems we see on every rigid plastics & closures floor, and why they happen.

The ERP, the lab, and the presses never connect

The ERP holds the jobs, quality lives in spreadsheets, and cycle data stays on the press HMI.

The floor is recorded on paper run reports

Operators fill in run reports, scrap tallies, and changeover checklists by hand at the end of the shift.

Scrap is counted at pack-out, so a cavity drifts all night

Short shots, flash, and dimensional rejects surface at inspection or in the carton.

Quotes assume standard scrap, so losing jobs are never found

The quote assumes the cycle the mold ran when it was new and the scrap rate everyone hopes for.

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 IQMS, Plex, Epicor, 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, quality, genealogy, and scheduling on one AI-native layer.

Can you get live data off our Husky and Netstal presses, blow molders, and closure 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, streamed into the AI layer in real time. Software and hardware agnostic, down to the Conair auxiliaries.

Can you trace a resin lot through the plant?

Yes. Lots are scanned at receipt, at the dryer and blender, at the press, and onto the finished carton. One-up, one-back genealogy in seconds, ready for the customer audit or the recall you hope never comes.

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 cycles, cavities, and resin lots on one live layer, so drift gets caught at the press instead of in the carton.

Start a scoping conversation →

ADJACENT FLOORS WE RUN

Corrugated & Boxes →Folding Cartons →Labels & Flexible Packaging →Plastics & Rubber →Contract Packaging & Co-Packing →