Summary
Overview
Work History
Education
Skills
Accomplishments
Certification
Interests
Recognized for creating a matrix used throughout the company to help managers identify training gaps
Timeline
Generic

Zachary Gerlock

Baltimore

Summary

As a Dynamic Process Improvement Lead at United States Gypsum, I leveraged Lean Six Sigma methodologies to significantly enhance production efficiency and operational consistency. I developed effective training systems and visual management tools, boosting team performance. Proficient in Minitab and Excel, I excel in collaborative settings, demonstrating strong analytical, communication, and teamwork skills. Highly adaptable, I thrive in dynamic environments, managing multiple priorities with a positive attitude. Committed to continuous learning and growth, I eagerly take on additional responsibilities to drive team success.

Overview

13
13
years of professional experience
1
1
Certification

Work History

Process Improvement Lead

United States Gypsum, USG
06.2023 - 10.2025
  • Responsible for executing business' continuous improvement goals
  • Analyze data to show trends to aid teams in root-cause problem solving using Lean Six Sigma tools
  • Self-motivated, with a strong sense of personal responsibility
  • Adapted seamlessly to assist new production lines and concepts with little to no prior knowledge of the process
  • Helped to make invisible problems visible through use of Visual Management
  • Worked effectively in fast-paced environments
  • Able to reach consensus in cross-functional teams to formulate plans and execute them
  • Skilled at working independently and collaboratively in a team environment.
  • Proven ability to learn quickly and adapt to new situations working with new production lines with no prior knowledge
  • Skilled in creating standard work for both production and management processes.
  • Created a database of video work instructions to improve consistency of training.
  • Demonstrated strong organizational and time management skills while managing multiple projects.
  • Worked with multiple productions lines to help solve their most pressing production issues

Lean Six Sigma Green Belt

United States Gypsum, USG
11.2017 - 03.2023
  • Facilitate problem solving events with two production lines to help teams reach consensus and develop improvement plans
  • Worked well in a team setting, providing support and guidance.
  • Performed production reconciliation assisting in managing inventory
  • Created standard work to improve training of new employees
  • Developed systems to assist management in identifying gaps within training
  • Self-motivated, with a strong sense of personal responsibility.
  • Act as a resource to help communicate issues on the production floor to the proper channels
  • Proven ability to learn quickly and adapt to new situations.
  • Excellent communication skills, both verbal and written.
  • Skills in statistical software (Minitab)
  • Developed and maintained courteous and effective working relationships with all leadership levels

Production Operator

United States Gypsum, USG
06.2012 - 11.2017
  • Operated machinery to ensure consistent production flow and quality standards.
  • Reduced downtime with proactive troubleshooting and timely resolution of equipment issues.
  • Maintained a safe working environment for myself and coworkers through the plant Safety Team
  • Reached top operator rate status within 2 years of service
  • Monitored production processes, identifying and resolving issues to maintain efficiency.
  • Collaborated with team members to optimize workflow and reduce downtime.
  • Trained new operators on safety protocols and equipment operation procedures.
  • Set up and adjusted machines for day-to-day operations.
  • Documented production information via daily system logs and discussed issues with management.
  • Boosted team productivity by training new hires and cross-training existing employees on multiple tasks.
  • Collaborated with management to develop strategies for continuous process improvement in production operations.
  • Calibrated, tested, and adjusted machine settings or controls in preparation for production operations.
  • Performed general equipment maintenance and repair to minimize downtime.
  • Inspected final products for defects and flaws using proper QA procedures.

Education

Lean Six Sigma Black Belt

TMAC
Fort Worth, TX
12-2024

LSS Green Belt - Lean Six Sigma

United States Gypsum CIC
Chicago, IL
06-2018

Skills

  • Friendly, positive attitude
  • Critical thinking
  • Active listening
  • Teamwork and collaboration
  • Customer service
  • Problem-solving
  • Time management
  • Flexible and adaptable
  • Calm under pressure
  • Problem resolution
  • Advanced skills in Excel and Minitab
  • Dependable and responsible

Accomplishments

  • Succeeded in a new role to the company as a full time green belt
  • Became a top operator on the cement board line within 2 years
  • Managed projects dictated in company's improvement plan necessary to keep our costs low in a highly competitive marketplace
  • Saved > $300,000 in 2025 by achieving 100% conversion to bulk unloading of key raw materials
  • Worked as a production lead managing a team of 4-5 people to work safely and efficiently
  • Created a catalog of training videos to help create new standards resolving a critical issue
  • Key member of the safety team for most of my tenure at the plant, and continued to work with those teams to implement their solutions
  • Created standards that were utilized at multiple plants and recognized by corporate management.

Certification

  • Certified Lean Six Sigma Green Belt, United States Gypsum - 6-2017
  • Attended LSS Black Belt classes in December of 2024

Interests

I keep a 125 gallon aquascaped freshwater aquarium, lover of animals, and I enjoy collaborative activities such as group improv I also enjoy video and board gaming and believe that it helps me think abstractly at strategies and what the most efficient way of completing a task might be, gamifying my life!

Recognized for creating a matrix used throughout the company to help managers identify training gaps

Created a matrix to determine which skills are necessary at a position, and level of training within each field to aid in identifying training gaps within production shifts.

Timeline

Process Improvement Lead

United States Gypsum, USG
06.2023 - 10.2025

Lean Six Sigma Green Belt

United States Gypsum, USG
11.2017 - 03.2023

Production Operator

United States Gypsum, USG
06.2012 - 11.2017

Lean Six Sigma Black Belt

TMAC

LSS Green Belt - Lean Six Sigma

United States Gypsum CIC

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Zachary Gerlock