Well, mystery solved. One of our techs (now former tech) failed to remove the protective sheeting before applying the backlit vinyl
.
The good news is, I can stop banging my head against the wall trying to figure out what went wrong and as a bonus, this was the easiest vinyl removal in the history of vinyl removal.
Thank you for all of your time and sorry for wasting it. Life was much easier when there were only a few of us working in the shop. This was at least a good training opportunity. We now remove the sheeting as soon as these sheets come in the door.