1. GARY R. SHELTON
3069 S. 1150 E. (765) 610-9313
Greentown, IN 46936 gshelton@borgwarner.com
Professional Profile
Seasoned professional with comprehensive experience and visible achievements in manufacturing and
innovation. Proven track record for implementing strategies that enhance design, productivity and profitability.
Accomplished in planning and executing projects from concept through production, with strong troubleshooting
and corrective action skills. Adept at assessing needs, and facilitating improvement. Detail oriented, organized,
and personable. Versatile team player who can incorporate new concepts and interact with all levels of
professionals. Possess Shainin Blackbelt certification.
Core Competencies
BlackBelt Certification & DOE
Purdue Mechanical Engineering Degree
Cross –Functional Teams
Cost Reduction Strategies
Project Management
Photography/Videography
Product/Process Development Authoring of Engineering Documentation
Quality Engineering SolidWorks 3D Modeling
Root Cause Analysis & Corrective Action Process Automation
Statistical Analysis Statistical Process Control
Automated Manufacturing
PPAP, PFMEA, DFMEA, PCP, & PFD
Validation Testing
Product Manufacturability
GD&T – I get the Datums!
Gauge R&R & Capability Studies (Cpk)
Professional Experience
BorgWarner Pendleton, IN
Senior Manufacturing Engineer 2014-2016
Support global facilities (China, Korea, Mexico, & USA) in resolving manufacturing and design issues. Interact with
product design engineers on new and existing products to optimize for quality and manufacturability. Develop and
deploy new manufacturing technologies and equipment.
Key Accomplishments:
• Project lead working with supplier to successfully develop and fabricate an automated conductor
former. Using patented technology, the former gently folds the wires rather than smashing into the desired
geometry. This equipment is 8 times faster than the current process and is a leap forward in technology,
minimizing conductor work hardening, spring back, and insulation damage.
• Managed conversion of DR29S production line in Mexico from 85 slot to 84 slot design. This
conversion consisted of replacing almost $1.8M of automated equipment and tooling. Responsibilities
ranged from justification of CapEx and interfacing with equipment suppliers down to detailing tool drawings.
This initiative resulted in an estimated annual savings of $832K.
• Developed and presented training material detailing how to program DC Drivers to insure properly
seated screws with appropriate clamp load.
• Authored Engineering Standards for Torque/Angle monitoring of threaded fastener installation, Welding
Electrode Clearance, and S-Form Conductor Geometry.
• Improved and optimized design of conductor forming & insertion tooling using SolidWorks 3D
modeling.

2. Gary R. Shelton, page 2
Saint-Gobain | Verallia Glass Muncie, IN
Senior Process Engineer 2010-2014
Supported 5 plants in North America with regular reviews and audits of their equipment. Negotiated service
agreements with equipment suppliers and championed multiple training sessions for the mechanics. Root caused
and provided corrective action for manufacturing issues, glass defects and inspection deficiencies. Visited customer
sites to address breakage and filling issues. Recognized by management as the “go to” guy for troubleshooting
production issues and identifying creative solutions.
Key Accomplishments:
 Negotiated Technical Service Agreements with Emhart Glass and MSC&SGCC Glass. These service
agreements brought in trained service technicians on a bi-annual schedule to examine the inspection equipment
and provide recommendations to return to OEM operational status. Negotiated reduced service pricing for the
TSA reviews.
 Implemented New Technologies throughout the Cold End.
 Pressure Sensitive Film to validate Squeezer Performance
 Use of data acquisition card to pull traces from Dual Head Gager and On-Line Thickness Gauge
 Transparent Gradient Labels to replace the black tape dots used for Challenge Samples
 Light Stations with Stress Detection
 Dedicated Digital Flow-meters for individual Polycoater Spray Heads
Entrepreneur Kokomo, IN
Inventor 2008-2010
After accepting a buyout offer from Chrysler (impending bankruptcy), I worked on developing a mechanically
morphing windmill patent for residential applications. Lack of access to SolidWorks and a 3D printer prevented
successful completion of a working prototype. I elected to re-enter the workforce in 2010.
Chrysler LLC Kokomo, IN
Warranty Specialist / Resident Engineer 1998-2008
Tracked warranty trends, identified root causes, and implemented corrective actions. Trouble shot production
issues, reducing scrap and improving through-put. Directed a team of technicians responsible for tear down and
road testing of field failures to identify and resolve warranty issues. Disseminated transmission training and warranty
information through the use of databases, meetings, and presentations. Interfaced with component and equipment
suppliers regarding implementation of new processes and design improvements.
Key Accomplishments:
 Founded and Chaired the Warranty Specialist Guild. Methods developed allowed Chrysler to more
effectively track and minimize millions of dollars in warranty costs. Consisted of 20+ Powertrain engineers
from various organizations within Chrysler. Objective was to gather and share “best practices” for identifying
and tracking warranty issues.
 Developed Reject Code mapping for the Valvebody test stands, increasing through-put from 60% to 97%
with an annual savings of $500K. Collaborated with the IT department to provide a system that converted
multiple reject codes into DNA code format. Results made it possible to match defects to reject code sequences
thus facilitating repairs as well as identifying defective components and assembly issues.
 Directed improvements to the transmission leak test process, increasing through-put from 83% to 95%
with a conservative savings estimate of $240K per year. Identified and resolved tooling, control logic,
maintenance, and programming issues.
 Managed improvements to the transmission pump gear rotor selector responsible for eliminating false
rejects, downtime, and overtime resulting in an estimated savings of $360K each year. Utilized an
external Analog to Digital card and pulled streaming data from the Sony (LVDT) probes which monitored end
face clearance. Determined that the gears were oscillating in the pocket during rotation.

3. Gary R. Shelton, page 3
Delco Electronics Kokomo, IN
Manufacturing Development Engineer 1989-1998
Developed automated mechanical shock equipment for testing air bag modules. Collaborated with both design and
validation engineering to provide manufacturability of products. Followed products from concept through production.
Evaluated, procured, and installed manufacturing equipment. Accountable for reviewing, approving, and
implementing cost saving proposals. Innovative with respect to mechanical design as well as product
improvements.
Key Accomplishments:
 Managed project conversion of shock equipment into a fully automated tester for all Delco Electronics
air bag modules. Utilization of this equipment has facilitated millions of dollars in sales. Responsible for
implementation in Kokomo IN, Malaga Spain, and Singapore. Systems are still in use to date and some were
recently installed in a facility in China.
 Developed and implemented a low cost design modification for the Cadillac air bag modules, preventing
need for major design changes. Conceptualized sealing the connector and case with RTV. Fabricated
prototypes and followed through with procurement and implementation of the manufacturing equipment required
to automatically seal the modules.
 Contributor of cost saving initiatives, leading to a savings of $850K during the first year. Participated in a
review panel which was challenged to develop and implement employee cost saving ideas.
 Created a low cost modification to test connectors that eliminated the potential for product impounds
and sorts. Integrated micro switch probes that mechanically scanned the product connector “keying” (internal
slot pattern), allowing ability to automatically verify that the connector supplier had applied the appropriate
barcode.
 Conceptualized the “self aligning test head”, after monitoring stresses on the circuit boards during all
production processes. Eliminated potential warranty issues and offered cost containment.
Magnavox Ft. Wayne, IN
Production Engineer 1984-1989
Planned assembly procedures for manufacturing and followed through with necessary written instructions, sketches,
and flow charts. Analyzed and initiated corrective action on mechanical production issues. Procured tooling
required for production.
Education
Bachelor of Science, Mechanical Engineering
Purdue University
Shainin Blackbelt Certification
Honors and Awards
Innovation Excellence Award; BorgWarner
Presidential Award; Delco Electronics
Patent for Rotary Circuit Board Solder Pallet Clip
Patent for Potting Material for under Hood Air Bag Sensors