     
|
|
|
|
|
Success in Manufacturing
Home Theaters is a TEAM EFFORT
By Sam Gazdziak
Published in CWB Custom Woodworking Business
Volume 11 No. 4 April 2001
|
|
 |
I don't think I would enjoy doing it."
That versatility has paid off nicely for the company. Fremont has
developed an expertise in entertainment centers and home theaters, which account for 25 percent
of the company's business. Those projects can range from a few thousand to more than $100,000.
Projects that involve home electronics tend
to come in two sizes - home theaters and entertainment centers. Home
theaters, which are dedicated rooms, can include several rows of seating,
multiple speakers and acoustical treatments on the walls and ceiling.
Gilchrist says that when Fremont Interiors is
working on home theaters, a collaborative effort leads to the best results.
Most customers also have interior designers and audio-video consultants
to work with Fremont on total design. In those cases, Fremont also works
as the project manager.
|
|
Fremont Interiors Inc. specializes in high-end
woodwork; what form that woodwork can take is constantly changing. The
Carmel, IN-based company can change from custom furniture to architectural
millwork to a reception desk to kitchen cabinets.
"Part of the reason I started my own business
is because I wanted to do the things I love to do, and that's design
and build furniture and cabinetry," says R. Kent Gilchrist, president
of the company. "If I had to do only one thing, only build kitchen
cabinets and not build the audio-video cabinetry and customer furniture,
|
 |
|
|
 |
"If the customer is adamant about a color,
then the interior designer can make custom window treatments to block
out the light, if that's an issue," says Joanna Menke, who along
with Gilchrist and Amy Adamson, is one of three designers on the staff.
If customers do not have an interior designer, one of the three on staff
will work with them.
One of Fremont Interiors' recent home theaters
has doors made of olive ash burl veneer center panels with a quartered
anigre veneer around the perimeter. Ash trim in the theater and around
the screen is stained steel blue. The company specified acoustical panels
on the walls of the theater and curved acoustical panel on the ceiling
and a granite floor in the lobby. They also built a dry bar and a wine
cellar in the lobby. There are two rows of tiered seating, and each
row has its own set of speakers. In addition, there are the standard
three front-channel speakers, two subwoofers and a 100-inch screen.
All of the electronic equipment is hidden behind one of the wall |
|
"If the client is a true audiophile who
wants the room to achieve a certain degree of sound quality, then the
AV consultant is going to make sure that it meets those needs. We, as
a cabinetmaker and designer, have to design around those criteria."
He adds that if customers don't have an AV consultant, he recommends
that they hire one.
Interior designers also play a major role in
home theater design. Certain colors are more reflective that others
and can cause glare, lessening the picture quality of the TV or movie
screen.
Designers can help pick colors that will lead
to a better viewing experience.
|
 |
|
 |
 |
has enough ventilation. Gilchrist says that
if a unit isn't properly vented, the heat buildup from the electronic
components can bubble the finish or warp the shelves.
| |
|
Fremont
Interiors use designers, audio-video consultants and customer
input to create the best results.
|
| |
Fremont Interiors is not limited to the local
area and has done projects throughout Illinois and Indiana and as far
away as Florida and the Caribbean. It has been able to expand by customer
referrals as well as being active in several associations. Fremont is
a member of the Architectural Woodwork Institute, National Kitchen and
Bath Association, and the American Society of Interior Designers. Aside
from finding supplier partners, membership in these
|
|
panels on a touch latch. The equipment is
on a rack system that slides out of the wall for easy access. Including
all of the electronics and lighting, the total cost of the room is more
than $250,000.
Smaller entertainment centers that are made
from a wall of cabinets do not have as many critical requirements as
home theaters. Still, Fremont Interiors has to ensure that the speaker
enclosures are not hurting the sound quality and that the unit
|
 |
|
|
 |
finish work, including stains, standard finishes,
glazes, crackle and distressing. Fremont uses DeVilbiss and Binks spray
guns and Mohawk and Guardsman finishing products. Three journeyman craftsmen
do all of the other wood and solid surface machining. They use a Striebig
vertical panel saw, a Powermatic table saw and shaper to make hardwood
trim and a Brandt edgebander from Stiles Machinery Inc. A typical lead-time
for complete entertainment centers is eight to 10 weeks, and about 12
weeks for home theaters.
Fremont also uses Salice and Hettich hardware,
Knape & Vogt full-extension drawer slides and Conestoga Wood Specialties
door and drawer boxes.
Menke says that its staff designers have also
spent time working in the shop. "We get hands-on experience building
cabinets or tops, so we have an understanding of what its like,"
she says. "When we meet with clients, we know what we're talking
about."
|
|
organizations has introduced the company to
designers and architects that work on high-end projects.
Fremont Interiors' nine employees all do multiple
jobs. One does all the engineering drawings and is working on the company's
new Web site and CD-ROM brochure. Production manager Sherry McLucas
runs all the Pattern Systems software (Draw Power for drafting, along
with AutoCAD, Cut Planner for optimizing and Drill Mate for tool path
set-up). She also runs the Weeke Optimat BP 12 CNC machining center
from Stiles Machinery.
A full-time finisher does all the
|
 |
|
|
The designers also play a role in educating
clients. Gilchrist says he has been working with one client for more
than a year, and the company has not cut the first piece of wood on
the project yet. (Customers do sign a design and documentation agreement,
so Gilchrist is being paid for his time.) Menke says that many customers
do not initially understand the cost of a project. Once she explains
the whole process, she says that customers understand why a home theater
can be a six-figure investment.
"Another misconception concerns the wood
species available. A lot of people don't know anything more than maple,
cherry, mahogany or walnut," says Gilchrist. "They don't know
that olive ash burl or sapele pommele or Japanese tamo ash is out there.
They come here and see something unique and different, and then they
get excited. They have a better understanding that, yes it's expensive,
but look at how much more they're getting. It's not going to be the
same product that their neighbor has."
Gilchrist adds that Fremont works with several
local veneer
|
|
suppliers, including Speer Veneer and Indiana
Architectural Plywood. The latter company also lays up panels for Fremont
when there are large quantities or over-sized panels.
Gilchrist says he would like to move the shop to a larger space. Fremont is in a 4,000
square-foot building, and he would like to add room for more production
and for a larger showroom. But he adds that being in a small space hasn't
hurt his company's output.
"Our machinery dealers love to bring clients
in here who complain that they don't have enough space to add a machine,"
he says. "It's surprising how efficient we can be with our space.
But our plan is to move into a bigger building."
The company's ability to do so many types of
woodwork has a couple of advantages. Fremont Interiors is able to do
whole-house projects, which also helps when the new home market gets
soft. Gilchrist says that a project that may have been just a $20,000
wall of cabinetry five years ago becomes a $150,000 project that covers
several rooms today.
|
|
|