BEAU ZABEL
White Pine
Summary
Results-driven Production Supervisor with 20+ years of experience in manufacturing, training, and operations management. Proven success in leading teams, optimizing production processes, and driving efficiency improvements through Lean Six Sigma and 5S methodologies. Strong track record of reducing defects, improving throughput, and enhancing employee engagement.
Overview
26
26
years of professional experience
Work History
Training Coordinator
Old Dominion Freight Lines
01.2015 - Current
- Developed and implemented site-wide training programs to improve operational consistency
- Led onboarding and certification processes for all employees, ensuring regulatory compliance
- Maintained and updated all training materials, fostering a culture of continuous improvement
Site Manager
Dandridge Components
01.2009 - 01.2015
- Directed daily production operations for Brunswick Boat brands, overseeing customer service parts, upholstery, and windshield manufacturing
- Applied Lean methodologies, using Lean Glass Wall to track performance and improvements
- Increased production efficiency from 22% to 88.5% while reducing customer failure rates from 21% to 1.95%
Production Manager
US Marine Upholstery
01.2005 - 01.2009
- Supervised 60–90 employees across multiple departments (Canvas, Foam, Upholstery, Vinyl, Woodshop)
- Spearheaded Lean Six Sigma initiatives, driving efficiency gains and cost reductions
- Key Achievements:
- - Upholstery efficiency improved from 71% to 98%, cutting labor and material costs by 20%
- - Canvas efficiency rose from 64% to 99%, with defect rates dropping from 16% to 2.3%
- - Led a $1.5M capital project to introduce molded foam production, achieving 100% efficiency in 3 months with a scrap rate below 5%
Maintenance Lead/Supervisor
US Marine Upholstery
01.2003 - 01.2005
- Implemented Total Productive Maintenance (TPM), reducing machine failures and downtime to
Maintenance Technician
US Marine Upholstery
01.1999 - 01.2002
- Maintained sewing machines, CNC equipment, hydraulic/pneumatic systems, and forklifts to ensure uninterrupted production
Education
High School - Graduated with Honors
Gatlinburg-Pittman High School
Gatlinburg, TNSkills
- Production & Operations Management
- Lean Manufacturing & 5S Implementation
- Employee Training & Development
- Process Optimization & Efficiency Improvements
- Safety & Compliance Management
- Team Leadership & Performance Coaching
Additional Skills And Certifications
- Lean Six Sigma Green Belt
- 5S & Continuous Improvement Expertise
- TPM & Preventative Maintenance Implementation
- OSHA & Safety Compliance
Timeline
Training Coordinator
Old Dominion Freight Lines
01.2015 - Current
Site Manager
Dandridge Components
01.2009 - 01.2015
Production Manager
US Marine Upholstery
01.2005 - 01.2009
Maintenance Lead/Supervisor
US Marine Upholstery
01.2003 - 01.2005
Maintenance Technician
US Marine Upholstery
01.1999 - 01.2002
High School - Graduated with Honors
Gatlinburg-Pittman High School
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