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Quality Manager
Barnes Reinforcing Industries —Gauteng, Gauteng
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Quality Manager
Barnes Reinforcing Industries —Gauteng, Gauteng
Lead root cause investigations (5 Why, Ishikawa, 8D). 5–8 years in metals manufacturing. Manage die and lubricant quality and their effect on drawn wire — die…
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Quality Manager

Barnes Reinforcing Industries -
Gauteng, Gauteng

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Job Details

Permanent
3 days ago

Full Job Description

QUALITY MANAGER
Wire & Fencing Manufacturing Plant

Reports to: Plant Manager
Reports to this position: Quality Controllers, Lab Technicians, Water Treatment Operator

PURPOSE OF THE JOB

Manage quality across the full product range, from incoming raw material to finished product on the despatch floor
Take technical responsibility for wire drawing and galvanising quality
Control the quality of incoming raw material and consumables
Oversee the effluent treatment plant and keep the plant compliant with its discharge licence
Lead the department from the floor, not from behind a desk

MAIN DUTIES

Raw material and consumable quality

Approve or reject incoming wire rod against chemistry, mechanical and surface specifications
Verify supplier cast and test certificates against actual test results
Control quality of zinc, flux and galvanising chemicals
Manage die and lubricant quality and their effect on drawn wire — die wear, coating pickup, surface finish
Assess supplier performance and manage non-conforming supplier material
Approve new suppliers and new consumable trials before they go into production

Wire drawing

Control drawn wire to spec: diameter, tolerance, tensile, elongation, torsion, wrap and surface finish
Investigate wire breakages, brittleness, scoring and coating pickup — root cause, not symptoms
Link drawing faults back to rod quality, die condition, lubrication or machine setup
Advise production where drawing practice is damaging wire properties

Galvanising

Take technical responsibility for coating quality
Oversee bath chemistry, bath temperature, immersion time and line speed control
Ensure coating mass, thickness, adhesion and uniformity are tested and within spec
Ensure pre-treatment (degreasing, pickling, rinsing, fluxing) is properly controlled
Investigate coating failures — bare spots, dross, flaking, white rust
Monitor zinc consumption and yield

Finished product quality — across all product lines

Set the quality standard, inspection points and acceptance criteria for every product line listed above
Ensure each line is inspected against its own spec: mesh aperture and squareness, barb spacing and grip, weld strength and weld integrity, wire tension, aperture consistency, coating condition after forming, dimensional tolerances, straightness, and finish
Ensure product marking, labelling, coil and bundle mass, and packaging meet customer and standard requirements
Verify that formed and welded product has not lost coating integrity in the process
Approve first-off samples on every product changeover
Sign off finished stock before it is released for despatch

Effluent and compliance

Oversee the effluent treatment plant and the operator running it
Ensure discharge stays within the water use licence and municipal by-law limits
Ensure sampling, records and statutory returns are done on time
Ensure hazardous waste (spent acid, zinc sludge, dross, ash) is stored, manifested and disposed of legally
Escalate compliance risks to the Plant Manager early, not after the fact

Quality management system

Own and maintain the ISO 9001 system
Keep the quality manual, procedures and control plans current across all product lines
Run internal audits and drive corrective actions to proper closure
Host external audits — certification body, SABS, customers, environmental inspectors
Report quality KPIs at management review

Leading the department

Spend the working day where the work is — on the floor, in the lab, at the lines. This is a management job, but it is not an office job
Be first on the scene when a quality problem stops production
Supervise, train, develop and discipline QC staff, lab technicians and the water treatment operator
Deploy inspectors across the product lines according to risk and production priority
Keep the lab equipped, calibrated and running to standard
Manage calibration of all test and measuring equipment
Manage the department budget

Customers and suppliers

Investigate customer complaints and issue formal 8D reports
Approve test certificates and certificates of conformance
Support sales on technical and specification queries
Handle customer and third-party product inspections

Improvement

Drive down scrap, rework and rejection rates across all lines
Lead root cause investigations (5 Why, Ishikawa, 8D)
Apply SPC to key process variables
Bring forward improvement projects with real savings attached

MINIMUM REQUIREMENTS

National Diploma or BTech/BEng in Metallurgy or Materials Science — not negotiable
5–8 years in metals manufacturing
At least 3 years managing a quality department
Solid galvanising background — must understand bath and coating control, not just read reports about it
Strong wire drawing background — rod, dies, lubrication and their effect on wire properties
Experience across a range of wire-formed and fencing products, not just one line
Experience overseeing industrial effluent treatment in a galvanising or similar environment
Has implemented and maintained ISO 9001 and been through external certification audits
Trained internal auditor (ISO 9001 lead auditor an advantage)
Knows the relevant SANS standards for wire, wire products, fencing and zinc coatings
Familiar with the National Water Act and municipal discharge requirements
ISO 14001 exposure an advantage

WHAT WE'RE LOOKING FOR IN THE PERSON

Understands wire metallurgy properly — drawing, annealing, failure modes
Knows galvanising well enough to walk up to a line and see what is wrong
Able to hold a standard across fifteen different product lines without letting the small ones drift
Works with data, not opinions
Technically strong enough to hold their own with the production managers, and to overrule them when the product is wrong
Will not fold when production pressure pushes for a shortcut
Can lead and develop a team, and hold people accountable
Computer literate — MS Office, ERP
Writes clearly enough for customer reports and statutory submissions

Work Location: In person

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