Summary
Overview
Work History
Education
Skills
Timeline
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Derek Demory

Warsaw,IN

Summary

Dynamic and results-oriented Manufacturing Leader with over 10 years of experience in high-volume production environments. Demonstrated success in driving operational excellence, cost reduction, and process optimization across manufacturing, engineering, and quality systems. Expertise in leading cross-functional teams, managing multi-million-dollar P&L operations, and executing large-scale capital projects. Skilled in implementing lean manufacturing, Six Sigma methodologies, and continuous improvement initiatives to achieve world-class performance in safety, quality, and on-time delivery. Proven communicator and mentor with a commitment to fostering innovation, accountability, and employee development.

Overview

13
13
years of professional experience

Work History

Manufacturing Director

Zimmer Biomet
02.2023 - Current
  • Full P&L responsibility for Warsaw West Campus Operations and Engineering which includes the manufacturing and sterile packaging of 3.3M implants annually, 1300 team members, and $675M in VOP.
  • Led $230M in capital expansion initiatives, scaling manufacturing capabilities and enabling the successful launch of 20+ innovative medical products.
  • Achieved best-in-class operational performance:
    • Delivered $23M in annual cost savings through lean transformations and productivity gains
    • Sustained >80% On-Time-In-Full (OTIF) delivery performance
    • Maintained a zero lost-time incident safety record

Manufacturing Associate Director

Zimmer Biomet
03.2022 - 02.2023
  • Directed operations for Extremities, Hips, Segmental, and Tibial Knee value streams, overseeing 200 direct labor employees and a leadership team of 20 salaried managers, supervisors, and engineers.
  • Led development and execution of the Strategic Plan for Warsaw West Campus, focusing on New Product Introduction (NPI) and manufacturing optimization initiatives.
  • Served as Operations lead during the 2022 FDA inspection, resulting in zero Form 483 observations—demonstrating strong compliance culture and operational discipline.

Manufacturing Manager

Zimmer Biomet
11.2018 - 03.2022
  • Oversaw all Production and Engineering activities for the Tibial Value Stream, managing a team of salaried supervisors and engineers, along with 90 hourly team members.
  • Delivered $4.8M in annual validated cost savings through process improvements and operational efficiencies.
  • Led execution of $12M+ in capital expansion projects to increase capacity and support new product launches.

Manufacturing Supervisor

Zimmer Biomet
10.2016 - 11.2018
  • Led first-shift operations for the Acetabular, Vitamin E, and Segmental Value Streams, overseeing four manufacturing cells and up to 65 hourly team members.
  • Managed first-shift operations for the Packaging Value Stream, directing a team of 200 responsible for sterile packaging of over 3 million implants annually.
  • Consistently delivered top-tier performance:
    • Achieved zero lost time incidents and zero product recalls
    • Maintained >98% on-time work order completion
    • Drove $2M+ in validated cost savings through process improvements and lean initiatives

Manufacturing Engineer

Zimmer Biomet
05.2015 - 10.2016
  • Provided hands-on manufacturing support and daily leadership using structured problem-solving methodologies to resolve production issues and improve efficiency.
  • Designed and implemented a visual management system across multiple manufacturing sites to promote daily accountability and embed Leader Standard Work practices.
  • Led cross-functional Kaizen events focused on reducing work-in-progress (WIP) inventory and manufacturing lead times.

Manufacturing Engineering Intern

Zimmer Biomet
01.2014 - 12.2014
  • Collaborated cross-functionally to plan and execute equipment and process validations (IQ, OQ, PQ) to ensure compliance and production readiness.
  • Developed alternate Bills of Materials (BOMs) and routing strategies to integrate secondary suppliers and enhance supply chain flexibility.
  • Applied Six Sigma and statistical analysis to historical data, driving improvements in manufacturing lead times and process stability.

Team Leader Internship

General Mills
05.2013 - 08.2013
  • Responsible for first shift operations of two packaging systems including twenty-one wage employees.
  • Provided hands on leadership while encouraging teamwork and process ownership.
  • Lead cost saving initiatives while driving zero loss and zero safety incidents

Engineering Operations Intern

General Mills
08.2012 - 12.2012
  • Completed continuous improvement project around scrap resulting in $450K in annualized savings
  • Collaborated with cross functional teams to execute projects critical to business needs.

Education

MBA - Operations Management

Ball State University
Muncie, IN
05-2018

Bachelor of Science - Biomedical Engineering

University of Toledo
Toledo, OH
05-2015

Skills

  • P&L Management
  • Cross-Functional Team Leadership
  • Talent Development & Succession Planning
  • Strategic Planning & Execution
  • Operational Efficiency & Cost Reduction
  • Six Sigma & Root Cause Analysis

Timeline

Manufacturing Director

Zimmer Biomet
02.2023 - Current

Manufacturing Associate Director

Zimmer Biomet
03.2022 - 02.2023

Manufacturing Manager

Zimmer Biomet
11.2018 - 03.2022

Manufacturing Supervisor

Zimmer Biomet
10.2016 - 11.2018

Manufacturing Engineer

Zimmer Biomet
05.2015 - 10.2016

Manufacturing Engineering Intern

Zimmer Biomet
01.2014 - 12.2014

Team Leader Internship

General Mills
05.2013 - 08.2013

Engineering Operations Intern

General Mills
08.2012 - 12.2012

MBA - Operations Management

Ball State University

Bachelor of Science - Biomedical Engineering

University of Toledo

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