DOJO TRAINING CENTER

 

 

Customer Satisfaction (PQCS)

Internal Waste / Cost Reduction

Sustenance / Internal PC

Execution Time-Line

 

Stage  Goal Deliverable
  • Scope Finalization and Project Plan Development
  • DOJO & Activity Finalization
  • Layout Development
  • Sequence Finalization for DOJO Training
Time Bound Low Cost DOJO Set Up
  • Shortlisting the Critical Process w.r.t. Safety, Productivity, Quality  & Cost
  • Department Matrix Development
  • Training Plan Drafting
  • SOP Drafting

Know My Company DOJO

  • Company Description, Founders History and Journey
  • Product & Geographical Coverage
  • Policy Document Finalization
Feeling Great Pride For the Company
  • Company Profile, Company Vision, Mission & value
  • Company Footprint & Product Portfolio, Customer Base & Geography
  • Research & Development, CSR Activities
  • Company Policy (HR, Safety and Others)

Safety DOJO

  • Basic Safety Guideline Development
  • Specific & Critical Safety Simulation Development
  • Safety Documentation
  • Virtual Reality Safety Simulation
Safety First For All Employee
  • 21 Impactful Safety Simulation & Games

Product DOJO

  • Product Range & Product Usage (Simulation)
  • Part – Product Matrix, Criticality of Product
  • Similar Product in Market
  • Simulation (Virtual Reality Based
Understanding of the Product and Its Criticality
  • Real Product Display
  • Usage Simulation
  • Similar Product in Market and Their Features
  • Criticality Understanding and impact of Consumer
  • 5 Senses DOJO
  • Touch Sense DOJO
  • Ambidexterity Simulation
  • Hand Eye Coordination
  • Hearing Sense
  • Seeing Sense
  • Sub-Conscious Mind Simulation
Use Human Sense For SPQC
  • 35 Innovative Simulation and Games for Activating the Human Sense

Process and Machine DOJO

  • Part Criticality Matrix
  • Start – Stop – Emergency Stop
  • Electrical Part, Electronic Part
  • Pneumatic & Hydraulic Part, Fasteners, Mechanical Part
Know The Machine and Be The Master
  • Critical Machine Part Display
  • Simulation of How Machine Operates
  • Possible Machine Failures and Mitigation Matrix

Production  DOJO

  • Abnormality Matrix, 4M Change Matrix
  • Work Instruction, Shop Floor Do’s Don’t
Skill on Production Process and Deviation
  • Display of All Production Document with Reference and Examples

Quality DOJO

  • Gauge Awareness
  • Best Practices of Using Gauges
  • Defect Gallery
Quality Focus in Everthing We DO
  • Display and Analysis of Defects So Far
  • Display of All Gauges and Videos of Best Practices Usage

Maintenance DOJO

  • Critical Tooling’s & Tool setting video
  • TPM Pillar Description ( If applicable)
  • Electrical & Mechanical LOTO
  • Hydraulics & Pneumatic Simulation
Best Practices for Maintenance and Safety During Maintenance
  • Simulation of all LOTO
  • Critical Maintenance Practices of Hydraulics, Pneumatics
On Job Evaluation and Certification All Documentation & Test
  • Test Sequence and Certification
Ergonomic DOJO Human Sustenance
  • Simulation of Standing, Walking, Sitting, Material Lifting
Innovation DOJO Improvement Technique
  • Kaizen Display, Karakuri Videos, LCA Techniques

Case Studies

DOJO Training Center Designing & Development

(Leading Wire Harness Manufacturer (Gurgaon))

Challenges : (Before Tetrahedron)

  • No DOJO Room across the plant
  • No Skill Up gradation Strategy
  • No flow established for proper training

Approaches : 

Tetrahedron DOJO Expert team charted a One Month project plan for DOJO Training Set-Up in 1100 Sq. Meter area. Developed a 3D Simulation and  process flow design validated with management team. Roles & Responsibilities of team developed and TMS onsite resource tracked the daily work progress. Two innovative products were developed by TMS team which are “Sensor Based Walking Speed Measurement “ devices and “ Standing Posture Evaluation Devices”

Results :

  • DOJO Center set up within time frame
  • 12 Levels of DOJO implemented

 

DOJO Training Strategy Integration with Existing HR Strategy

(Leading Automotive Manufacturer (Rudrapur))

Challenges : (Before Tetrahedron)

  • Only Safety and Maintenance DOJO were present in DOJO room
  • No awareness of DOJO Training among the Employee

Approaches : 

Tetrahedron DOJO Expert team charted a One –Month project plan for DOJO Training Set-Up in 2500 Sq. Meter area. Developed SOPs and documentation of DOJO training strategy. Implemented  “DOJO Strategy Manual” including DOJO Score Card, Training effectiveness Measurement System. and linked the  DOJO strategy with Skill level of the workmen

Results :

  • Department wise DOJO training sequence developed
  • Skill  matrix integrated with DOJO training
  • DOJO On Job Training (OJT) KPIs are developed and tracked
  • On Paper Performance Evaluation System Implementation
  • Video based & Poster based learning system developed

Why DOJO Center ?

DOJO Center is required to create awareness of Skilling & Right-skilling of the new workforce & Re-skilling of the existing workforce to refresh manufacturing concepts and educate them about Company awareness,Safety awareness,5 Senses, Innovation and Technical skills.Skilled manpower can contribute in company profitability growth  through Customer Satisfaction, Internal Waste Reduction and Sustenance Strategy.

Customer Satisfaction (PQCS) (1)

Manufacturing DOJO Levels

We setup sequence of dojo training in  4 Phases  and  12 DOJO Gates

  • Initiation
  • Demonstration
  • Evaluation
  • Sustenance
Dojo

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