DOJO TRAINING CENTER

Customer Satisfaction (PQCS)

Internal Waste / Cost Reduction

Sustenance / Internal PC

WHAT IS DOJO

DOJO (अखाडा ) is a place to practice. This is a Japanese word meaning let’s do it. The DOJO center mainly focuses on imparting practical training, simulated training & game training for a specific process in manufacturing.

Genesis: One can remember that when one starts learning riding a bicycle or start learning the car, the first couple of days one has to see the pedals/accelerator/clutch/breaks to apply, and after some days of practice one can apply the breaks/clutch/pedals easily without seeing this. So What happens during the practice period: The frequent practice helps one’s senses (refer to the 5 senses of a human being) to remember the applications and thereby improvising the human body parts movement and motor control.

The same methodology of DOJO i.e. frequent practice leading to human sensory activation can be used for manufacturing process like assembly, part picking & fitting, material lifting, measuring, etc

DOJO TRAINING FOR 50% FASTER SKILL IMPROVEMENT

The DOJO centers are designed to cater 3 levels of skill improvement

  • Skilling  of new operators who joined recently (Skill Level 0, 1, )
  • Right-Skilling on a specific process (Skill Level 2)
  • Re-Skilling of the existing workforce (skill Level 3 and 4)

The innovative simulation used in DOJO can reduce the overall training & skill development lead time by 50% as compared to conventional training.

Skill Level Upgradation Conventional Training Lead Time DOJO Training Lead Time
Level 0 to Level 1 8 Days 3 Days
Level 1 to Level 2 15 Days 8 Days
Level 2 to Level 3 45 Days 21 Days
Level 3 to Level 4 180 Days 90 Days

The DOJO centers are designed to cater 3 levels of skill improvement

  • Skilling  of new operators who joined recently (Skill Level 0, 1, )
  • Right-Skilling on a specific process (Skill Level 2)
  • Re-Skilling of the existing workforce (skill Level 3 and 4)

The innovative simulation used in DOJO can reduce the overall training & skill development leads time by 50% as compared to conventional training.

Skill Level Upgradation Conventional Training Lead Time DOJO Training Lead Time

Level 0 to 1

8 Days

3 Days

Level 1 to 2 15 Days

8 Days

Level 2 to 3 45 Days

21 Days

Level 3 to 4 180 Days 90 Days

DOJO FOR BUSINESS RESULT

One of the main focus areas of the DOJO center is to achieve business results by improving human sense and skill related. These business results are as follows :

SAFETY

PRODUCTIVITY

QUALITY

COST

There are many hand-eye coordination games that are generally put in DOJO training centers. While these game good to improve the Touch and Seeing senses, the effectiveness and relevance of the games with the actual shop-floor activity are questionable.

Any DOJO center must be aligned to achieve the business objective e.g. Productivity, Safety, Quality, and Cost by skill improvement.

SKILL MATRIX INTEGRATION WITH DOJO TRAINING

Almost all manufacturing has a skill matrix for customer audit purpose, for ISO / IATF standard requirements. However, the main purpose of any customer audit, or ISO / IATF standards is to ensure the skill matrix is updated + accurate and used for Production Planning, Weekly Off Allocation, Work Allocation, Career Progression, and Skill Improvement Plan.

Skill Matrix document is used properly will achieve remarkable improvement in skill as well as business results. Else it becomes a piece of paper that will be opened just 1 day before the customer visit/system audit.

DOJO set up, with a focus on real + required skill improvement, enables the integration of the actual & measurable skill level and the skill improvement trend of each and every employee. The integration of skill improvement is done based on the consistency of the employees’ skill level adherence in DOJO Practice

DIFFERENT DOJO SEQUENCE

DOJO 1: KNOW MY COMPANY DOJO

OBJECTIVE :

  • Employees should take great pride in their association with the organization. This helps create trust and a long-lasting employee-employer relationship

 

EXAMPLES :

  • Company Profile
  • Company Vision, Mission & Value
  • Company Founders and History
  • Company Footprint & Product Portfolio
  • Customer Base & Geography Coverage
  • Research & Development
  • CSR Activities
  • Company Policy (HR, Safety, and Others)

DOJO 2: SAFETY DOJO

OBJECTIVE :

  • Safety First For All Employee

 

EXAMPLES :

  • Safety Pledge
  • Safety Sign Colour Simulator (4 Colours)
  • Fire Extinguisher application 
  • Fire Hydrant Application
  • Fire Triangle
  • PPE Matrix & PPE Usage
  • Falling from Height simulator ( Harness)
  • Safety Shoe simulator
  • Hand Safety Simulator
  • Head Safety Simulator ( Helmet)
  • Eye Wash simulator
  • Safe walking speed Simulator
  • Fire Safety Board
  • Electric Safety Board
  • Dust Mask simulation
  • Nose (Smell) DOJO
  • Noise Protection Simulation
  • Waste Management
  • Gas Cylinder Safe Handling
  • CPR and First Aid
  • Emergency Exit Simulation (Virtual Reality Base)

DOJO 3: PRODUCT DOJO

OBJECTIVE :

  • Understanding of the Product and Its Criticality

 

EXAMPLES :

  • Product Range
  • Product Usage (Real Sample)
  • Product Usage (Simulation)
  • Part – Product Matrix
  • Criticality of Product
  • Similar Product in Market
  • Simulation (Virtual Reality Base)

DOJO 4: 5 SENSE DOJO

OBJECTIVE :

  • Use Human Sense For SPQC

 

EXAMPLES :

  • Touch Sense – Blind Box Weight Sensing
  • Touch Sense – Blind Box Size Sensing
  • Touch Sense – Blind Box Shape Sensing
  • Touch Sense – Blind Box Similar Part Sensing
  • Touch Sense – Blind Box Diff Part Sensing
  • Touch Sense – Rotation Angle Sensing
  • Touch Sense – Length Sensing
  • Touch Sense – Torque Sensing
  • Touch Sense – Heat Sensing
  • Touch Sense – Hand Stability During Movement (Welding)
  • Ambidexterity – Limb Speed Comparison
  • Ambidexterity – 2 Hand 2 Bin Same Part
  • Ambidexterity – 2 Hand 2 Bin Diff Part
  • Ambidexterity – 2 Same Activity
  • Ambidexterity – 2 Similar Activity
  • Ambidexterity – 2 Different Activity
  • Hand-Eye Cord – Electric Wire Test Set
  • Hand-Eye Cord – Same Size Pin Set
  • Hand-Eye Cord – Diff Shape Pin Set
  • Hand-Eye Cord – Reverse Colour Pin Set
  • Hand-Eye Cord – Reverse Board Pin Set
  • Hand-Eye Cord – Coloured PIN Set
  • Hand-Eye Cord – 6 Angle Screw Set
  • Hand-Eye Cord – 6 Angle Bolt Set
  • Eye ( Seeing) Sense – Select The Right Fit Tool
  • Hearing Sense – 6 Set Same Decibel Sound
  • Hearing Sense – 6 Set Diff Decibel Sound
  • Hearing Sense – Gear Knock Sound
  • Hearing Sense – Vibration Sensing
  • Smelling Sense – Fuel Smell
  • Smelling Sense – Chemical Smell
  • Smelling Sense – Electric Wire Burning Smell
  • Closed Eye Simulation – Assy Process Seq
  • Sub Conscious Mind – Time Count DOJO

DOJO 5: PROCESS & MACHINE DOJO

OBJECTIVE :

  • Know The Machine and Be The Master

 

EXAMPLES :

  • Critical Machine Simulation
  • Part Criticality Matrix
  • Start – Stop – Emergency Stop
  • Electrical Part
  • Pneumatic Part
  • Electronic Part
  • Hydraulic Part
  • Fasteners
  • Mechanical Part

DOJO 6: PRODUCTION DOJO

OBJECTIVE :

  • Skill in Production Process and Deviation

 

EXAMPLES :

  • Abnormality Matrix
  • 4M Change Matrix
  • Work Instruction
  • Shop Floor Do’s Don’t
  • Visual Management

DOJO 7: QUALITY DOJO

OBJECTIVE :

  • Quality Focus in Everything We DO

 

EXAMPLES :

  • Gauge Awareness
  • Best Practices of Using Gauges
  • Defect Gallery
  • Poka-Yoke

DOJO 8: MAINTENANCE DOJO

OBJECTIVE :

  • Best Practices for Maintenance and Safety During Maintenance

 

EXAMPLES :

  • Critical Tooling’s & Tool setting video
  • TPM Pillar Description
  • Electrical Maintenance & LOTO
  • Mechanical Maintenance & LOTO
  • Hydraulics DOJO Simulation
  • Pneumatic DOJO Simulation
  • Gear Functioning Simulation

DOJO 9: ON JOB TRAINING

OBJECTIVE :

  • All Documentation & Test

 

EXAMPLES :

  • Training KPIs
  • Visual SOPs

DOJO 10: CERTIFICATION

dojo CERTIFICATION

DOJO 11: ERGONOMICS DOJO

OBJECTIVE :

  • Enable employee to reduce fatigue for better health

 

EXAMPLES :

  • Standing Posture Simulation
  • Sitting Posture Simulation
  • Material  Lifting Posture Simulation
  • Ankle Bend Simulator
  • Elbow Bend Simulator
  • Waist Bend Simulator
  • Stretching Posture Simulation
  • Pulling and Pushing Simulation
  • Walking Speed Simulator
  • Ergonomics Best Practices Videos

DOJO 12: INNOVATION DOJO

OBJECTIVE :

  • Improvement Technique

 

EXAMPLES :

  • Low-Cost Automation Simulation
  • Kara-Kuri Material Handling System
  • SCAMPER Technique
  • Kaizen Demonstration
  • Mind Mapping Demo
  • Aerial Map Demo

1.Identify Critical Process

  • Frequent Quality Issue
  • Low Productivity
  • Fluctuating Productivity
  • Inadequate Skill
  • Major Safety Concern
  • Freq Cust Complaint
  • Newly Added Process
  • Irregular Process
  • Cycle Time > TAKT
  • Freq M / Power Change

2. Video Shoot

  • Capture the video of the critical process. At least 10 repletion of the process is required for a better observation
  • Limb Movement
  • Torso Movements
  • Body Posture
  • Tool Usage
  • Interview & feedback from the operator also should be taken

3. Develop OAT

  • From the video develop the OAT (Operation Analysis Table). The duration of each elemental activity should be no more than 1 minute.

4. List Out ”Work” From Oat

  • Identify the work element from the OAT which you want to convert into DOJO simulation and on which you want to train the operator

5. Refer Activity Sense Chart

  • See – Measure Dimension, Observe Mark, Observe Colour, Pick and Place, Moving Object
  • Hear – Sound (Vibration, Friction, Gas Exhaust, Piece Creaking, Electric Sparks, Material Touch, Impact, Leakage)
  • Smell – Smell (Chemical Leakage, Material Burning, Fuel Burning, Electric Spark)
  • Touch – All type of Limb Motion, Pick and Place, Feel Vibration, Weighing, Lifting, Measure Temperature, Handling Touch Material

6. Create Simulation / Game

  • The Sensory Skill Improvement Game / Simulation is developed by a structured process of “Magnify – Minify – Just” which will enable the senses to adopt the skill quickly.

7. Facilitate For Skill Training

  • Develop the SOPs for DOJO Training, Evaluation,  Re-Skilling and On Job Training (OJT) and 5-Level Skill Matrix

8. Measure Existing Skill Level

  • Measure the existing skill level of the trainee based on skill level (before the trainee goes for DOJO Training)

9. Integrate Skill Trend in S.Matrix

  • The DOJO simulation while being practiced by the employees, their actual skill level, and improvement trend is to be captured in the organization skill matrix.

10. Reskilling

  • Selecting the next process training for skill level 3 and 4

DOJO MANUAL

DOJO Manual is a structured document with all SOPs, Scopes, Training Methodologies, Test Administration to be followed in DOJO Center, This document is a one-stop guide for the DOJO Master / Trainer.

  • Objective
  • Scope
  • Term & Definition
  • Responsibilities Matrix
  • DOJO Training Room Layout
  • DOJO Training Sequence
  • DOJO Room Content
  • DOJO Sequence Departmental Matrix
  • DOJO Training Time Chart
  • Procedure for DOJO Training
  •  Phase 1: Preparation
  •  Phase 2: DOJO Training Execution Flowchart
  •  Phase 3: Performance Evaluation
  • DOJO Assessment for Skill Matrix
  • Annexure 1: DOJO History Card
  • Annexure 2: Evaluation Questioner (Test Series)
  • Revision History
  • Authorization Note

To get a copy of the DOJO Manual, List of Equipment, Simulation

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 the management team. Roles & Responsibilities of the team developed and TMS onsite resource tracked the daily work progress. Two innovative products were developed by the 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 was 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 the DOJO training strategy. Implemented  “DOJO Strategy Manual” including DOJO Score Card, Training effectiveness Measurement System. and linked the  DOJO strategy with the 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

Gallery

Testimonial

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