Position Overview
At ExactoCraft, our day-to-day success relies on the precision, consistency, and reliability of our core plastic injection moulding operations. We are seeking a highly active, hands-on Quality Process Controller who will be a constant, visible presence on our production floor. You will be directly responsible for auditing manufacturing parameters, executing line inspections, verifying operator output, and stepping in to guide, coach, and uphold our strict quality control processes.
Because our factory operates 24 hours a day, maintaining seamless quality standards across all hours is critical; therefore, the successful candidate will be required to work shifts on occasion to support and audit different teams.
While your immediate focus will be stabilizing and maintaining the high standards of our current factory operations through rigorous floor-level process verification, ExactoCraft is on a growth trajectory. We are actively expanding our capabilities with high-volume, mass-production automation, including a brand-new automated Extrusion Blow Moulding (EBM) line. This role is specifically structured for an ambitious professional who wants to master our current processes first by leading from the front, and then step up to help manage document control, coordinate internal audits, and maintain our ISO 9001 standard as the facility scales. If you have a sharp technical eye and want to be trained into a Quality Manager, this role offers the perfect runway.
Key Responsibilities
1. Process Auditing & Technical Parameter Control (Core Task)
- Manufacturing Process Audits: Audit the manufacturing process systematically using Process and Product Audit checklists to ensure all inputs match specific parameters (including raw materials, machine temperatures, and physical settings).
- Material Verification: Perform incoming inspections on buy‑out products, ensuring all raw materials meet the factory’s Incoming Inspection Criteria for each consignment received.
- Test & Validation Runs: Maintain a physical presence at all engineering test and validation runs to verify parameters and ensure samples conform to specifications.
- Scrap Analysis & Reporting: Verify and record daily scrap data per shift. Generate formal scrap reports and actively present feedback on scrap percentages and the highest defect contributors during the Daily Operations meeting.
- Non-Conformance Tracking: Immediately log and produce an exception or non-conformance report for any process or product test that falls outside of approved specifications.
2. Floor Inspections & Team Guidance
- Active Inspections: Routinely check the quality of work being done by production floor packers, ensuring all parts match engineering specifications and approved samples.
- Coaching & Guidance: Actively guide and mentor packers on the floor, correcting mistakes in real-time and teaching them how to uphold our higher quality standards.
- Sampling Governance: Monitor the production floor to ensure that all required Sampling Procedures, Quality Description Sheets (QDS), and In-Process Inspection Records (IPIR) are filled out completely and correctly.
- Subordinates: Quality inspectors will report to the Quality Process Controller. The role requires leading a small team and coordinating their work effectively.
3. Systems Growth, Expansion & Document Control
- New Line Integration: Assist in adapting and implementing quality checks and processes for all new production lines.
- Document Governance: Take charge of the factory's document control system, ensuring all floor check sheets, logs, and procedures are at the correct revisions and properly filed.
- SOP Creation: Help draft and update standard operating procedures (SOPs) for new and existing processes, routing them through our formal engineering approval process.
- ISO 9001 Alignment & Calibration: Maintain daily paperwork to keep the factory fully compliant and ready for external ISO 9001 audits. Continually monitor the calibration status of all active inspection and measuring equipment on the floor.
Candidate Profile & Requirements
Qualifications & Experience
- Schooling: Matric / Grade 12 (NQF 4) with strong mathematical literacy is a minimum requirement.
- Professional Training (Beneficial): Completion of a Quality Assurance training course or certificate (e.g., basic quality control, internal auditing, or operations control) will be highly advantageous.
- Technical Training (Beneficial): Any formal technical tertiary qualification or mechanical training that supports quality and process control in a plastic environment is a distinct advantage.
- Experience: Minimum of 2 years of hands-on experience in a similar role within a manufacturing or engineering environment, specifically within plastic injection moulding or packaging processing.
- High-Volume Mindset: Experience working in a fast-paced environment where mass production requires sharp attention to detail despite fast cycle times.
- Shift Flexibility: Willing to work occasional night or weekend shifts when needed for production schedules or audits, in a plant that operates around the clock.
- ISO Familiarity: Basic understanding and operational alignment with ISO 9001 standards.
Key Skills & Attributes
- Technical Eye: Strong mechanical aptitude with the ability to read technical drawings and comfortably use precision measuring tools (e.g., vernier callipers).
- Communication & Leadership Traits: A confident, assertive, yet collaborative communication style. You must be comfortable checking other people's work, providing input at daily operations meetings, and firmly but constructively guiding operators to improve.
- Organized & Computer Literate: Highly structured approach to paperwork and proficient in basic computer skills (specifically Microsoft Excel) for manual and electronic data logging, trend tracking, and scrap reporting.
- Operational Mindset: Capable of handling high work pressure, managing daily forward planning, and working effectively under ISO procedural guidelines (OP 6, OP 11, OP 12, OP 13, OP 14, OP 15).
Education:
- High School (matric) (Required)
Work Location: In person
