Shawn Ramey
Crawfordsville,IN
Summary
Results-driven Director of Operations with over 26 years of experience in the manufacturing sector, adept at thriving in fast-paced environments. Proven expertise in Lean manufacturing principles, waste elimination, and change management to optimize production processes and achieve measurable results. Demonstrated ability in strategic planning, team development, and cross-functional leadership to drive operational excellence and foster a culture of continuous improvement. Committed to leveraging extensive industry knowledge to enhance productivity and elevate organizational performance.
Overview
27
27
years of professional experience
Work History
Director of Operations
Acuity Brands, Indiana Production Facility
Indiana
01.2021 - 01.2026
- Responsible for P&L of the facility.
- Maintained positive financial performance year over year.
- Averaged 10% productivity improvement year over year.
- Cost avoidance and saving of $2.9M
- Managed 2 facilities totaling 350K sqft, with 700+ employees.
- Responsible for all aspects of Safety, Quality, Delivery, Inventory, and Productivity.
- Safety improvement from 4.29 to 1.7 incident rate through initiative-taking actions.
- Average of 17% improvement in quality.
- Reduced late to customer from 4.6 days late to .4 days late.
- 10.7M dollars in inventory reduction. Drove inventory accuracy actions allowing for best results accomplished for physical inventory 3 yrs consecutively.
- Carbon Emissions reduction of 32%
- Drive employee engagement measured by annual employee engagement survey.
- Drive 10pt improvement of score and increased participation from 76% in year 1 to 98% in years 2, 3, and 4. Accomplished through creating and executing annual actions.
- Collaborated with local community to create a development program for front line leaders, improving employee engagement.
- Created a program for talent development, allowing for 70% internal promotions.
- 2020 into 2021 lead facility consolidation with no impact on quality and delivery.
- Developed a relationship with the local community to change the perception of the organization both internally and externally.
Director of Operations
Acuity Brands Lighting, Minnesota Production Facility
Minnesota
01.2019 - 01.2020
- Responsible for P&L of the facility.
- Manage 120-150 employees.
- Transformation of a struggling facility to one that was winning on all fronts.
- 31% improvement in quality metrics
- 30% improvement in On Time Delivery, from 68% to 98%
- 17% improvement in productivity
- 15% reduction in carbon footprint
- Converted a team that was failing, connecting them with a change mindset, allowing them to win and see the importance of what they do.
- Consolidated two facilities, getting all processes into one location.
Focus Factory Manager
Acuity Brands Lighting
Crawfordsville
01.2011 - 01.2019
- Responsible for P&L of an Assembly and Fabrication Focus Factories.
- Manage 150-200 employees, including 21 salary employees – 4 Buyer Planners, 4 Manufacturing Engineers, 10 Supervisors, and 3 Post-Sales Associates.
- Developed 10 manufacturing associates, 4 into Buyer Planners and 6 to Supervisors, 2 Buyer Planners to Manufacturing Engineers, 4 Engineers / Buyer Planners to Focus Factory Managers.
- Introduced behavior-based safety program, with employee driven audits, driving reflector fabrication from an injury rate of 18 to 1.56.
- In 2012 major safety hazard removed from Focus Factory of responsibility by transforming the layout, successfully separating forklifts and pedestrian work areas.
- Year over year customer delivery performance, driving an area experiencing 2 days late to 3 hrs. late on average. Maintained less than 2 hrs. of late for 3 yrs consecutively, accomplished through driving supplier performance and driving internal Kanban process.
- Demonstrated the ability to reduce inventory days through reducing supplier lead time, driving responsible areas to 12.5 days of on hand inventory, 40% reduction year over year.
- Successfully lead projects for space creation, freeing up 35,000 sqft of floor space for new business.
- Lead 2 product moves, from other facilities with 0 impact to customer delivery.
- Demonstrated an average of 14% productivity growth year over year. Accomplished through driving standard work events and eliminating waste in manufacturing processes.
- Responsible for leading new product introduction on the manufacturing side, introducing an average of 4 new products per year.
- Reduced LT to the customer from an average of 10 days to 5 days or less.
Manufacturing Engineer Manager
Acuity Brands Lighting
Crawfordsville
01.2010 - 01.2011
- Managing the Engineers and Bom/Routing Specialist.
- Responsible for Lean transformation schedule – scheduling and completion of Kaizen events for fabrication areas.
- Implement Kanban process throughout the fabrication areas, including teaching the Buyer Planners the Kanban process.
- Drove SMED and TPM events, process resulted in set-up reduction time from avg. of 30 min to avg. of 7 min in turret presses.
- Implemented manual schedule card process in the back shops, eliminating transactions as material flows through the process.
- Created FIFO processes and lanes for each of the back-shop departments.
- Led cross-functional teams to enhance manufacturing processes and improve product quality.
- Conducted root cause analysis for process disruptions, driving corrective actions and improvements.
Manufacturing Engineer
Acuity Brands Lighting
Crawfordsville
01.2008 - 01.2009
- Transformation of assembly areas from conveyer lines to single piece flow cells.
- Layout of assembly areas to flow material in and out of cells.
- Lead standard work events, developing standard work for all assembly products.
- Drive the implementation of 5S principles.
- Developed and executed process improvements to enhance product quality and reliability.
- Conducted root cause analysis to identify and resolve production issues effectively.
- Developed technical documentation, including standard operating procedures, work instructions, and engineering drawings to support manufacturing operations.
Fabrication Area Manager
Acuity Brands Lighting
Crawfordsville
01.2006 - 01.2008
- Manage of fabrication areas including metal stamping, bending, welding, and cnc machine centers.
- Lead project to implement standard turrets, which allowed the reduction of 1 shift of work due to efficiency gains.
- Transformed layout of turret and press brake area to create flow through the process, reducing the transportation of material from one process to the next.
- Improved conversion cost by 25% by increasing unit production in weld and stamping areas.
- Reduced factory supply expense in the area by $90,000 annually.
Assembly Area Manager
Acuity Brands Lighting
Crawfordsville
01.2001 - 01.2006
- Oversee all assembly activities.
- Responsible for manning assembly lines.
- Managing 7 supervisors 200 employees.
- Mentoring and coaching 7 supervisors.
- Ensuring production levels are maintained and safety practices are consistently followed.
- Handling union grievances and problems.
- Special projects: Assembly line layouts, troubleshooting new processes, team member of six sigma projects.
Supervisor
Acuity Brands Lighting
Crawfordsville
01.1999 - 01.2001
- Supervision of assembly lines, 20-40 employees.
- Oversee daily production / efficiency reporting.
- Troubleshooting assembly issues and assembly line engineering.
- Oversee product quality, coaching, and counseling responsibilities.
Education
Master of Business in Administration -
Indiana Institute of Technology
Indianapolis, IN05.2007
Bachelor of Science - Industrial Technology
Ball State University
Muncie, IN05.1998
Skills
- Strategic planning
- Budget development
- Operational efficiency enhancement
- Vendor/Union Negotiations
- Collaborative leadership
- Lean production techniques
- Team building
- Risk mitigation strategies
Timeline
Director of Operations
Acuity Brands, Indiana Production Facility
01.2021 - 01.2026
Director of Operations
Acuity Brands Lighting, Minnesota Production Facility
01.2019 - 01.2020
Focus Factory Manager
Acuity Brands Lighting
01.2011 - 01.2019
Manufacturing Engineer Manager
Acuity Brands Lighting
01.2010 - 01.2011
Manufacturing Engineer
Acuity Brands Lighting
01.2008 - 01.2009
Fabrication Area Manager
Acuity Brands Lighting
01.2006 - 01.2008
Assembly Area Manager
Acuity Brands Lighting
01.2001 - 01.2006
Supervisor
Acuity Brands Lighting
01.1999 - 01.2001
Master of Business in Administration -
Indiana Institute of Technology
Bachelor of Science - Industrial Technology
Ball State University