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!
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, TX12-2024
LSS Green Belt - Lean Six Sigma
United States Gypsum CIC
Chicago, IL06-2018
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
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