Zach Thornton
Homer Glen,IL
Summary
Dynamic senior leader with over 15 years of comprehensive experience in maintenance, production, and warehousing operations. Strong advocate for safety, complemented by a proven track record in automation that drives continuous improvement initiatives. Recognized for strategic execution and an acute understanding of operational dynamics, ensuring efficiency and effectiveness at every level. Committed to fostering a culture of excellence and innovation within teams to achieve organizational goals.
Overview
20
20
years of professional experience
1
1
Certification
Work History
Warehouse Operations Manager
G3 Enterprises
03.2024 - 05.2025
- Managed the startup of a new 310,000 sq ft warehouse supporting both customer service and the operations teams
- Successfully onboarded 2 new customers in collaboration with the sales and business development teams with standard operating procedures for all functions in place. Continue to meet customer SLA expectations that resulted in expansion of business with a 2nd warehouse.
- Responsible for $5M annual operating budget with monthly operating cadence with HQ in California
- Management of over 30+ team members from leads, associates, and operators. Worked with talent acquisition to recruit and hire a team of qualified operators and ensured successful completion of all onboarding requirements.
- Established onsite safety, inspection and performance program for equipment operators. Mentor and coach team members.
- Meet customer auditing requirements: weekly, monthly, and annually. Audits completed to date with minor discrepancies
- Utilize warehouse management system expertise to drive inventory record accuracy (IRA) above standard targets
- Initiated facility improvement projects including the installation of automatic dock locks and rail shelters for improved safety and visibility, HVAC overhauls to improve heating and efficiency, and implemented new racking for greater storage density to meet inventory needs
- Daily management of various contractors and vendors in support of existing projects to ensure on-time and under budget delivery
- Fleet management of 20+ forklifts, 3 stretch wrappers, 1 compressor, scissor lift, and floor scrubber. Established daily inspection and maintenance programs with local equipment providers
- Providing Industrial Real Estate, Packaging, Equipment, Sand, Labels and Logistics solutions
Warehouse Operations Manager
G3 Enterprises
08.2022 - 03.2024
- Managed existing 250,000 sq ft warehouse in a growth stage with a P&L of $3M annual operating budget
- Created standard operating procedures for new customers and ensured site compliance through use of internal audits
- Everyday started with a safety first mindset, removing obstacles and ensuring all direct reports follow safety guidelines
- Responsible for company-wide innovation pilot improvement using automation. Successfully managed from startup to production the installation of a fleet of autonomous reach forklifts to reduce customer payload damage rates and improve facility production capability.
- Managed transition of WMS from Fort to Softeon without impact to daily operation
- Providing Industrial Real Estate, Packaging, Equipment, Sand, Labels and Logistics solutions
Senior Team Leader – Warehouse Operations
E&J Gallo Winery
02.2022 - 08.2022
- Responsible for the daily rail and inventory operations for 2 million sq ft facility
- Provide daily and weekly business updates with KPIs to Senior Leadership
- Ensured the overall safety and responsibility of all team members
- Provided training and coaching as needed for new processes and any updates related to standard work
- Mentored and developed the growth of 7 level five technical operator for future success within the organization
- Supervised a diverse team of 50+ team members that include Full time, Continuous Ops, and Part Time schedules
- Responsible for 24-hour end to end process for both the rail and receiving teams
- Managed fleet of 18 automatic guided vehicles (AGV), 50+ forklifts, stretch wrappers, automated layer pick machines, automated case pick solution
- Maintained a fleet of 113 Five buggy carts to meet production needs with both upstream and downstream applications
- Deployed a train tracker dashboard to reduce downtime and provide visual management of buggy location
- Global industry leader in wine and spirits distribution.
Advanced Team Leader – Bottling Production
E&J Gallo Winery
05.2017 - 02.2021
- Responsible for 30 team members of varying assignments to include machine operators, technical operators and maintenance mechanics
- Worked cross functionally with cellar, warehousing, and quality teams to ensure compliance to standard
- Directly managed shift mechanics during downtime events and planned preventive maintenance activities
- Led and participated in root cause analysis, Gemba, kaizen and other continuous improvement disciplines
- Executed weekly sanitation protocols as required by quality assurance department across production line
- Performed daily pre-shift meetings to review daily activities and goals with the team
- Launched new production line to increase production capacity by 40%
- Reported out daily metrics on overall equipment efficiency
- Global industry leader in wine and spirits distribution.
Maintenance Supervisor
Graham Packaging Inc
02.2016 - 05.2017
- Directly managed the maintenance department responsible for the support of 2 production sites: 13 manufacturing lines with over 20 different machine centers. Championed predictive maintenance schedules and supported all root cause analysis for unplanned equipment downtime.
- Analyzed daily metrics to improve overall equipment efficiency (OEE) of all production lines and deployed total productive maintenance (TPM) strategies for continuous improvement
- Implemented line automation solution with Kuka Robotics resulting in a 15% increase in OEE
- Managed end to end projects that required outside contractors and or vendors
- Managed safety training and oversight of safety program for all maintenance staff
- Managed 24x7 operation with a team of 17 maintenance mechanics
- Designs, manufactures, and sells custom containers for food, beverages, household and automotive products.
Journeyman Mechanic Team 1
Owens Corning Inc
08.2013 - 02.2016
- Responsible to the maintenance manager for accurately reporting on the health of 300 pieces of manufacturing equipment
- Utilized various tools and heavy machinery to complete both scheduled and reactive work orders
- Maintained a safety first mindset through all maintenance activities and had zero safety incidents
- Material innovation company that offers products for buildings and construction
Enlisted - Canvassing Area Recruiter
United States Marine Corps
08.2010 - 08.2013
- Operation Enduring Freedom (Afghanistan)
- 31st Marine Expeditionary Unit
Enlisted - Airframes structures mechanic
United States Marine Corps
11.2005 - 08.2010
- Operation Enduring Freedom (Afghanistan)
- 31st Marine Expeditionary Unit
Education
Master of Business Administration -
University of Phoenix
07.2017
Bachelor of Science - Manufacturing Operations
University of Phoenix
11.2015
Skills
- ADP, SAP 60, MS Office, Leading 2 Lean, Attendance Enterprise, Softeon, Fort, Swiss log, Python, Visual Basic, Elixr
Certification
- Ives Certified forklift trainer - Nov 2024
- Lean Practitioner - May 2018
Timeline
Warehouse Operations Manager
G3 Enterprises
03.2024 - 05.2025
Warehouse Operations Manager
G3 Enterprises
08.2022 - 03.2024
Senior Team Leader – Warehouse Operations
E&J Gallo Winery
02.2022 - 08.2022
Advanced Team Leader – Bottling Production
E&J Gallo Winery
05.2017 - 02.2021
Maintenance Supervisor
Graham Packaging Inc
02.2016 - 05.2017
Journeyman Mechanic Team 1
Owens Corning Inc
08.2013 - 02.2016
Enlisted - Canvassing Area Recruiter
United States Marine Corps
08.2010 - 08.2013
Enlisted - Airframes structures mechanic
United States Marine Corps
11.2005 - 08.2010
Bachelor of Science - Manufacturing Operations
University of Phoenix
Master of Business Administration -
University of Phoenix