This is what bugged me about the last season of the series -- if it wasn't the Vito bullshit, it was less on the Soprano family and more on the revolving door across the bridge. Characters were introduced then killed off in two or three episodes.

With that, I suspect Gerry was made long before Season Six. There's the celebration dinner at Vesuvio in "Luxury Lounge" -- the promotion of Gerry to permanent Capo and the making of Burt Gervasi. At the beginning of the season, Gerry was an acting Capo as Phil was acting Boss with Johnny Sack in jail.

Regardless, it's a rather rapid rise through the ranks.