Resume for Gary E Casterline

1. GARY E. CASTERLINE
7895 Raglan Drive • Warren, OH 44484 • Mobile 330-240-2543 • gcasterline@gmail.com
SUMMARY
Accomplished expert in plastics engineering with a proven history of choosing the best material
for applications, known for successfully troubleshooting component needs and results. Focused on
responding to client needs and providing on time solutions.
• Material Selection • Processing
• Specifications • Product Design
• Mold Flow Interpretation • Failure Analysis
• Training Processing and Design • Managing Plastics Teams
• Physical and Analytical Test Methods • Customer/Supplier Liaison
PROFESSIONAL EXPERIENCE
DELPHI CORPORATION (formerly PACKARD ELECTRIC DIVISION OF GENERAL MOTORS
CORPORATION) Warren, OH
STAFF PROJECT ENGINEER IN PLASTICS (a management level engineer) 2004-2009
SENIOR MATERIALS ENGINEER IN PLASTICS 1982-2004
Referred to within Delphi as the global plastics “expert”. Developed web based data systems to
allow essential plastics related information such as properties, design limitations, processing
information or training materials to be available at all times without having to contact the expert
directly. Developed material approval process for new applications or designs. Developed a global
corporate plastics engineer’s collaboration network team and used it to consolidate specifications
among different divisions and solve regional plastics problems.
• Analyzed hundreds of failed plastic parts; successfully diagnosed the failure mode and
suggested economical, robust solutions.
• Developed an electrical connector design change to fix a common breakage complaint where
previously no solution was evident; eliminated a $250,000 quality problem.
• Implemented a process equipment change for making convoluted tubing which saved $100,000
in material cost during the first year.
• Saved hundreds of thousands of dollars in vehicle and wiring harness assembly line downtime
and replacement parts through innovative temporary solutions to plastic related performance
problems.
• Trained at least 4000 Delphi hourly and salaried employees on various aspects of plastics as
well as many customers, so they could better understand how to design more robust parts, build
more plastic friendly molds or process plastics in a way that would be less damaging to the
material.
• Made changes to a two piece, ultrasonically welded lamp socket that reduced the failure rate
from 25-100% to zero.
• Trained 1000 people in design of experiments (DOE) so various departments could have at
least one DOE trained employee to guide their organization.
• Ran a development molding lab to determine a tooling and process strategy for a new plant
which eventually turned into an implementation plan for three 60 machine precision molding
plants.
PAULSON TRAINING PROGRAMS, Chester, CT
CONTRACT INSTRUCTOR through Orbital Consulting for ProMolder 1 Course 2006-Present
Taught students for three day sessions at various sites across North America using course
materials developed by Paulson for the purposes of laying the foundation for further training on
more in depth molding capabilities. This involves both class work and a molding lab study.

2. Gary E. Casterline – Page 2
EDUCATION
Masters of Science in Industrial Administration (11 month accelerated program), Krannert
School of Management at Purdue University, W. Lafayette, IN, General Motors Fellowship
Recipient
Bachelor of Mechanical Engineering – Plastic Processing, General Motors Institute (Kettering
University), Flint, MI – Cooperative Training at Oldsmobile in Lansing, MI
AFFILIATIONS
• Society of Plastics Engineers (1987-Present) – Two term (non-consecutive) President of
Cleveland Section including 2008-9. Previously active in positions including chairman of
programs, awards, public interest, education and website development. Received Outstanding
Achievement Award from Cleveland Section in 2005.
• President of Lake Erie Wine Society (1989-Present)
PATENT
• New seal geometry for improved sealing between plastic surfaces that are not completely
parallel with each other
PROFESSIONAL DEVELOPMENT
• Delphi Problem Solving Process
• Shainin Apprentice Certification
• Product Liability, Law and Litigation Training
• SPE Annual Technical Conference Training for last 15 years
• Ethics Training
• Basic Trainer Skills
• Design of Experiments/ Taguchi Metheds
ADDITIONAL ACCOMPLISHMENTS
• Member of Delphi Nanomaterials development team
• Member and chairman (2 year term) of the General Motors Plastics Committee
• Worked closely with MoldFlow analysis group to suggest alternative gating locations or product
designs that would lead to reduced warpage, flow hesitation in hard to vent areas or material
selection optimization.
• Worked closely with finite element analysis group to suggest design alternatives that would lead
to part configurations that would perform flawlessly within the capabilities of the plastic material.
• Responsible for plastic material selection for 500 new designs per year.
• Authored more than 20 global plastics and testing specifications per year.
TECHNICAL SKILLS
Word, Excel, PowerPoint, Access, Outlook, Netmeeting, Optical Microscopy, CPR and Basic First
Aid