Tonic Chauke
Brakpan
Summary
I’m a Process, Quality, and Production Engineer with ~5 years of hands-on experience helping manufacturing teams work smarter, faster, and more efficiently. I’ve led Lean Six Sigma projects that saved over R3.5 million a year, set up ISO-compliant quality systems from scratch, and managed plant expansion projects worth over R5 million +, while keeping production running smoothly. I enjoy solving process challenges, whether that’s cutting waste, improving product quality, or making sure different sites follow the same high standards. My background in ink manufacturing and colour systems is backed by strong skills in data analytics using Power BI, ERP systems, and team training. At my core, I’m about making processes clearer, people more capable, and results more consistent - all while keeping things practical and team-focused.
Overview
3
3
years of professional experience
Work History
Process and Quality Engineer
Precision Inks (Corruseal Group)
Johannesburg & Cape Town, South Africa
09.2023 - Current
- Developed and implemented full ISO 9001 & ISO 22000-compliant QMS, including document hierarchies, internal audit plans, traceability trees, and CAPA systems.
- Integrated Power BI process dashboards across the production floor, enabling line managers to monitor waste, OEE, and downtime in real-time.
- Designed multi-step ink reclaim and recycling process, saving ~R700K annually in pigment usage and reducing environmental discharge.
- Unified site SOPs, testing protocols, and release standards across three regional plants, improving consistency and operational efficiency.
- Collaborated with finance and procurement to link mass balance analytics to cost drivers, influencing R&D formulation cost control.
- Performed full FMEA reviews for new dispenser machine installations, mitigating 12+ identified risks before commissioning.
- Piloted automated barcode tracking for raw material usage, improving stock accuracy from 82% to 97%.
- Spearheaded root cause investigations into citrus customer complaints using 8D framework - cutting total complaints by 55% in 6 months.
- Led R5 million CAPEX projects including plant layout redesign, automated dispensing unit installation, and commissioning of closed-loop viscosity control systems.
- Drafted URS documents and coordinated vendor evaluations for high-speed mixers and pigment-dust extraction systems.
- Directed operator training, FAT/SAT validation, and risk-based changeover planning for all new equipment.
- Delivered 100% uptime during changeover projects, with no disruption to client delivery schedules.
- Led daily formulation, correction, and QC approval of high-precision water-based and solvent-based inks, ensuring compatibility across diverse substrates (kraft, linerboard, PET).
- Introduced automated batch tracking and non-conformance logs, reducing QA rechecks by 40%.
- Developed an in-house ink calibration reference database using spectrophotometry and viscosity indexing, reducing formulation turnaround time by 50%.
- Instituted 5S methodology in the ink lab; improved layout, reduced material search time by 60%, and increased lab productivity by 35%.
Quality Ink Technician
Detpak Packaging SA (Mpact Group)
Johannesburg, South Africa
02.2022 - 08.2023
- Designed customer-specific ink formulas for high-speed Flexographic presses, handling up to 6 product types/day.
- Initiated ink “first-pass” protocol that increased first-time-right output from 82% to 96% within 4 months.
- Standardised colour matching procedures using CIELAB tolerancing, reducing client rejects due to shade variation by 60%.
- Aligned Detpak's ink system with FSC, BRCGS, and GMP audit requirements, enabling export clearance to EU clients.
- Built colour libraries and master formulas, enabling easier replication and lower variation during shift changes.
- Rolled out “Kanban-style” visual stock system for inks, reducing press-side ink retrieval time by 70%.
- Developed ink BOMs and consumption reports, feeding data to Shopware ERP for more accurate MRP and purchasing decisions.
- Mentored 6 junior technicians and provided hands-on training in QC techniques and corrective action
Graduate Ink Lab Technician
Flint Group
Johannesburg, South Africa
02.2022 - 03.2022
- Carried out raw material QC, colour matching, pH/viscosity control, and press-readiness tests across 15+ SKUs weekly.
- Assisted in trial blends and custom colour match approvals for FMCG and pharmaceutical clients.
- Created standard test protocols and improved the documentation process for product release forms.
- Supported NCR resolution through RCA methods and ensured updates were reflected in SOPs and corrective logs.
- Applied 5S in ink lab areas, achieving full audit readiness in line with ISO 9001 practices.
Education
Bachelor of Science - Chemistry With Chemical Engineering
University of The Witwatersrand
Johannesburg, South Africa 01.2021
Skills
- Process & Quality Systems: ISO 9001, ISO 22000, BRCGS, GMP, FSC compliance; QMS design; SOPs; Control Plans; Risk Assessments
- Lean Manufacturing & Continuous Improvement: Six Sigma, DMAIC projects, OEE optimisation, Waste & Rework Reduction
- Root Cause Analysis & Corrective Action: 5 Whys, FMEA, Ishikawa, 8D Reporting
- Ink Manufacturing Expertise: Water, Solvent and UV-based Inks, Colour Matching, Ink Dispensing, Custom Formulation
- Data Analytics & Digital Tools: Power BI, Excel VBA, SPC Monitoring, Mass Balance Systems
- CAPEX Project Management: Plant Layout Design, Equipment Commissioning, Automation Projects (R10M Scale)
- ERP & Systems Integration: SAP, Shopware Integration with Production and Quality Control
- Team Leadership & Training: Cross-Functional Upskilling (10 Staff), Change Management, Process Standardisation Across Sites
Accomplishments
- R3.5 million+ annual savings through Lean Six Sigma process improvements.
- 96% compliance on external audits across ISO9001 and BRCGS
- Led R5 million+ CAPEX projects with minimal production disruption.
References
- Ozyf, Adam, Greg@Precisionink.co.za, 066 475 1730, Precision Inks, Production & Technical Manager
- Rudolf, Keller, RKeller@detpak.za.com, 074 589 8747, Detpak Packaging SA, Operations Manager
Timeline
Process and Quality Engineer
Precision Inks (Corruseal Group)
09.2023 - Current
Quality Ink Technician
Detpak Packaging SA (Mpact Group)
02.2022 - 08.2023
Graduate Ink Lab Technician
Flint Group
02.2022 - 03.2022
Bachelor of Science - Chemistry With Chemical Engineering
University of The Witwatersrand