Da-Lite is well-known as an industry leader in the projection screen market, working hard to develop a reputation for consistently providing quality product and superior customer support. There are also some downsides to having a 100+ year history. For instance, you might get called a “dinosaur” from time to time. Ouch.

We’re far from extinction though. Things are always changing at Da-Lite. Growing. Adapting. Evolving. We invite you to explore what’s new, and how we’re investing in our future, constantly striving to better serve the AV market.

This blogpost series will cover continuous manufacturing improvements, technological advancements, and customer service diligence. The passion and dedication of Da-Lite employees is one of its best assets. We want to share that story with you.

Da-Lite employees outside newly remodeled headquarters in Warsaw, Indiana, May 2017.

One Team

Sr. Director of Operations, Tony Hill, and Manager of Operations Engineering and Maintenance, Chris Loos, are spearheading big efficiency gains on the Da-Lite manufacturing floor in Warsaw, Indiana. Over the past year, they faced a number of challenges that resulted in significant changes to the facility. Their goals: reduce inefficient dependency between departments, simplify flow of materials, better utilize manufacturing space and increase energy savings.

Investing in the right people in the right positions was paramount. Leadership and support teams were evaluated for each value stream. A planning manager and manufacturing engineer were added to the team among other managerial positions. Focus shifted away from temp labor to extensive training of full-time staff, working smarter rather than overtime.

A solid foundation of cross-training was established first, following a rule of three employees crossed-trained in roles or skills for each area. Tactical thinking and mentorship of promising talent played a large role in supervisor training as well. The results: better teamwork and cohesive thought which sped up production and improved product lead times.

 

 

Da-Lite employees test Fast-Fold frames before routing the product to Shipping.

Streamlined Manufacturing

Other efficiency wins are due to investment in equipment and improved flow of raw materials through the manufacturing process. New saws reduce time to cut wooden cases from twenty minutes to five. Upgraded hoists assist with testing and cleaning screens in preparation for shipping. Tables for cutting screen surfaces and spraying borders increase capacity and allow for creation of larger screens.

Screen size is growing to keep pace with industry demand for projection of bigger and brighter images and large-scale installations. Achieving larger than life images often requires seaming the screen surface. Seams can be unsightly and distract from projected imagery. To combat this problem, Da-Lite Operations and R&D are collaborating with IR equipment manufacturers to implement state-of-the-art surface welding machinery. This new technology produces what Senior Director Matt Graham calls “ghost welds.” The joined screen material is so flat the seam is barely visible.

 

New hoists allow for testing and cleaning of electric screens as they grow in size to meet market demands.

Little time is wasted, whether fulfilling an order from stock or designing customized projection screen solutions. New, large carousels that house and transport surface fabrics prevent excessive handling before building screens, drastically decreasing damage and scrap. Positioning surface carousels and other materials closer to manufacturing areas lessens transport time. “Some parts used to travel nearly 800 feet through our facility from storage to manufacturing,” said Tony Hill. “Now they travel only 40 feet or less.”

Surface carousels feed directly to cutting tables.

Overall, floor space is better utilized to focus on Da-Lite’s core competencies. Flexibility in all areas of manufacturing is crucial for Da-Lite to maintain customizations, which are a key part of the business. Always ready to serve AV market needs, whether it be custom black drop, special sizes or other configurations, everyone at Da-Lite takes pride in working one on one with customers to find creative solutions for any installation.

Customized products, like this simulation dome, are a vital part of Da-Lite manufacturing.

Continuous Improvement

Energy savings and environmental concerns were also top-of-mind throughout the process of restructuring the facility. Installation of new variable speed air-cooled air compressors reduced annual water consumption by 15%.

“Our goals for 2019 include installing LED lighting throughout the Warsaw plant and parking lot, eliminating current T8 bulbs, while maintaining light motion sensors throughout the facility. This will save 356,000 KWH annually. We’re planning to maintain the Screen Green^® recycling program as well,” explained Chris Loos. Screen Green^® allows customers to send old surfaces to Da-Lite, keeping them out of landfills.

These improvements are in addition to environmentally-friendly practices already established at Da-Lite facilities which include:

• During the remodel of all offices, meeting rooms and the cafeteria at the Warsaw facility in 2017, lighting was converted to LED with motion sensors.
• A water cooling system was eliminated in July 2017, resulting in 300,000 gallons of water saved annually.
• In January 2018 a starch wrap machine replaced heated shrink-wrap operations, saving 65,725 KWH annually.
• Da-Lite eliminated paper work orders for daily production schedules and introduced a data capture and storage system to turn all incoming correspondence into digital files to create a virtually paperless office.
• A recycling center was created in the employee parking lot in Warsaw, which is illuminated by solar-powered lighting.
• Da-Lite encourages vendors in its supply chain to use recyclable packaging for components.
• Open-air circulation in manufacturing facilities is used during summer months to reduce power consumption by 19%. Heat is also recovered in the winter, saving 479,500 KWH annually.
• Da-Lite facilities are certified to the ISO 14001:2015 and ISO 9001:2015 standards.

“We have the best people - committed to doing the hard work, the right thing and always looking out for the customers,” says Da-Lite Director of Screen Technology, Tim Henson. That drive to continually improve and succeed is evident everywhere you turn at Da-Lite. Whether it be in manufacturing, product management or customer care, everyone is focused on being the best choice for your image.

Like and follow Da-Lite to learn how Da-Lite is building a solid foundation for future generations in upcoming blogposts. Up next: understand how R&D, product management and engineering work together to innovate and improve projection screen technology.