1. JOHN D. DeMASIE
168 Pine Hill Drive (478) 271-0016 (H) (478) 308-2548 (C)
Cochran, GA 31014 jddemasie@hotmail.com
PLANT MANAGER / LEAN DEPLOYMENT MANAGER / CONTINUOUS IMPROVEMENT MANAGER
Operations Manager with proven leadership ability, an excellent plant performance record, and expertise in the
application and direction of Six Sigma, Lean Manufacturing and Project Management programs. Demonstrated
accomplishment in the deployment and implementation of Lean Manufacturing Systems (Toyota Production
System) delivering superior performance in safety, quality, customer service, and cost. A creative results oriented
leader with change agent energy and mentality. Expertise includes:
• Operations Management / Union • Project Management
• Strategic Planning • Procurement and Inventory Management
• TPS Lean Manufacturing Deployment • Budget Planning and Cost Control
Master Black Belt
PROFESSIONAL EXPERIENCE
J D Lean Consulting 10/2009 – Present
Lean Manufacturing – Toyota Production System – Lean Consulting Service
MBB Lean Deployment Director - Contract
Florida based LED Lighting Design and Manufacturing Plant
• Manufacturing introduction of new product – LED Lamp – for major (2) big box retail stores
• Developed manufacturing method, designed manufacturing tooling, and created standard work for new product
introduction. SMT/Through-hole printed circuit board manufacture, lamp assembly, packaging.
• Reduced labor content of A19 product by 60% utilizing lean cellular manufacturing principles.
ACUITY BRANDS LIGHTING / LITHONIA LIGHTING, Conyers, Georgia 1985 - 9/2009
North America’s leading manufacturer of lighting fixtures, with revenues over $2 billion.
Director, Procurement Management 2009 – 9/2009
Cochran, Georgia Manufacturing Plant, 500,000 sqft, 800 union employees
• Directed the inter-plant sourcing of component parts across all US and Mexican fixture manufacturing operations
• Reduced total company inventories by $5MM by developing lean procurement strategies and directing the
relocation of available inventories from operation to operation to consume excess materials.
• Manufacturing Team Leader for the Innovation Group (LED new product design team)
• Designed and prototyped light fixtures utilizing LED technology.
• Patent searches active for 3 of the prototypes designed and constructed.
Director of Operations – Cochran Manufacturing Plant 2006 – 2009
• Directed the Lean Manufacturing Continuous Improvement Program
• Shingijutsu Global Consulting Lean Manufacturing Training
• Trained for 10 Days in Nagoya, Japan by Mr. Shimura, Executive Director, Shingijutsu Global Consulting, in
Standard Work, 5S, SMED, Visual Management, and TPM.
• Achieved Environmental “Green” Status
• Improved finished good quality from 3 Sigma to 4.5 Sigma
• Employed Standard Work and Poka Yoke processes to improve finished goods quality.
• Reduced FG lead times from 12 days to 7 days by:
• Reduced changeover times in the fabrication areas (SMED).
• Initiated Kanban inventory system.
• Created single piece flow assembly operations.
• Reduced manufacturing costs by 20%, $7,000,000 by:
• Completely cellularized the manufacturing operation.

2. JOHN D. DeMASIE
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• Installed Visual Management tools and data driven management practices.
• Installed Value Stream /Focused Factory matrix management organization.
• Reduced Raw and WIP Inventories utilizing Kanban, from $12MM to $7.5MM.
Director – Acuity Business Systems Lean Manufacturing 2004 – 2006
Crawfordsville Indiana Manufacturing Plant
• Directed the initiation of a data driven Lean Manufacturing / Continuous Improvement deployment program in the
Crawfordsville, Indiana operation.
• Reduced FG lead times from 15 days to 7 days by:
• Instituted Standard Work and SMED in the reflector spinning and forming operation.
• Instituted Standard Work and PULL materials flow through Anodizing.
• Reduced manufacturing costs by 30%, $3,500,000 by:
• Completely cellularized the manufacturing operation improving productivity by 55%.
• Reduced Raw and WIP Inventories utilizing Kanban, SMED, from $10MM to $6MM.
Director of Projects, Supply Chain Development - Manufacturing 2002 –
2004
• Relocated products from/to four facilities in three countries on time to budget saving $10,000,000 per year by:
• Project Director for closure of 3 Canadian manufacturing operations to Monterrey, Cochran, and Crawfordsville
manufacturing plants.
• Project Director for closure of Berkeley, CA manufacturing operations to Monterrey manufacturing operation.
• Project Director for relocation of selected manufactured products from Cochran manufacturing plant to Monterrey
manufacturing plant.
Director of Operations – Cochran Manufacturing Plant 1992 – 2002
3 Manufacturing Plants, 650,000 sqft, 1,600 union employees
• Reduced manufacturing costs by 15%, $12,000,000 per year by:
• Doubled the manufacturing output of the facility from $600K to $1.2 Million (Factory Cost) per day.
• Achieved and maintained the highest productivity performance for all LL manufacturing operations.
• Reduced FG Lead times from 20+ days to 12 days.
• Reduced Raw and WIP Inventories from $22MM to $12MM.
• Negotiated 3 Union contracts.
Production Manager – Cochran Manufacturing Plant 1985 – 1992
EDUCATION
Bachelor of Science, Industrial Engineering, Purdue University
West Lafayette, IN
AWARDS AND PROFESSIONAL SERVICE
Lean Master Black Belt
Acuity Brands President’s Safety Award
Acuity Brands Chairman’s Award
President – Cochran Rotary Club
Chairman – Bleckley County Hospital Authority
Director – United Way of Bleckley County
Member – Middle Georgia College Foundation
Director – State Bank of Cochran