DOJO TRAINING CENTER
Manufacturing Training Dojo : Empowering Workforce Excellence
- Safety DOJO
- 5 Senses DOJO
- Process Specific DOJO
- DOJO 2.0
- Maintenance DOJO
- DOJO Room Layout
- DOJO Manual
What Is DOJO
DOJO (अखाडा ) is a place to practice and learn. This is a Japanese word meaning let’s do it. The DOJO Training Center mainly focuses on imparting practical training, simulated training & game training for a specific process in manufacturing.
Origin: You can remember that when anyone starts learning to ride a bicycle or a car, the first couple of days he has to see the pedals, accelerator, clutch, or breaks to apply, and after some days of practice, he can apply the breaks, clutch, or pedals easily without seeing them. So what happens during the practice period? The frequent practice helps his senses (refer to the 5 senses of a human being) to remember the applications, thereby improvising the human body’s movement and motor control.
The same methodology goes for DOJO in Manufacturing i.e. frequent practice leads to human sensory activation that can be used for manufacturing process like assembly, part picking & fitting, material lifting, measuring, etc. With the use of Safety DOJO, 5 Senses DOJO, Process Specific DOJO, DOJO 2.0, DOJO Safety Board and so on, workers and team members can re-train their skill set and gain knowledge in a DOJO Training Center.
Dojo Center Work Concept
A DOJO Center is well-known for the manufacturing companies where newly brought in team members can receive professional training and acclimate just to take on their duty effectively to work on the manufacturing shop floors. To complete a particular task in a DOJO Center, he or she are trained again and again with the help of replica models and mock-ups until they becomes perfect at their task. There are many experienced trainers to train the newly hired workers who given confidence to the new operators and give time-to-time guidance to correct them. After taking training from Dojo Training Center, a worker feels more comfortable on the shop floor and performs his work better!
DOJO Training Center equipment’s and the training staff at Tetrahedron are amply equipped to deliver the various training programs. A diligent worker at a DOJO Training Center is repeatedly and methodically trained in a certain skill by using mock-ups or replica models till they master in it. In making the training straightforward and targeted, we hope to foster two-way communication! While also being considerate of the perspectives our team members at.
a. Fully equipped for diverse training programs
b. Methodical training process
c. Encouraging effective communication and teamwork
DOJO center layout for different Industries
DOJO Training For 50% Faster Skill Improvement
The dojo training for manufacturing 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 Training Center Setup 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 |
DOJO Training For Manufacturing Industries
One of the main focus areas of the DOJO centre is to achieve business results by improving human sense and their skill. These business results are as follows :
Enhance Safety through Awareness
Productivity and Cycle Time Improvement
Quality Improvement and Defect Reduction
Manpower Cost Optimisation
There are many hand-eye coordination games that are generally put in DOJO training room. While these games are good to improve the touch and visual senses, the effectiveness and relevance of the games with the actual shop-floor activity.
Any DOJO center must aligned with business objective such as Productivity, Safety, Quality, Moral, Delivery and Cost by skill improvement.
Skill Matrix Integration With DOJO Training
Almost all manufacturing has a skill matrix for customer audit purposes, for ISO/IATF standard requirements. However, the main purpose of any customer audit, or ISO/IATF standard is to ensure the skill matrix is updated, accurate, used for Production Planning, Weekly Off Allocation, Work Allocation, Career Progression, and Skill Improvement Plan
Skill Matrix Document when used properly will achieve remarkable improvement in skills as well as business results. Otherwise it becomes a piece of paper that will be opened just a day before the customer visit/system audit.
DOJO Set Up, with a focus on required skill improvement, enables the integration of the actual & measurable skill level and improvement trend of each and every employee. DOJO can be used to make real time and actual skill matrix of employee. The integration of skill improvement is done based on the consistency of the employees’ skill level adherence in DOJO Practice. –
12 Steps For Dojo Training
DOJO 1: Know My Company DOJO
Objective :
The purpose of “Know My Company Dojo” is to enhance employees’ understanding and engagement with company operations and culture
Examples:
♦ Company Profile
♦ Company Vision, Mission & Value, Goal Statement
♦ Company Founders and History
♦ Company Footprint & Product Portfolio
♦ Customer Base & Geography Coverage
♦ Research & Development
♦ CSR Activities
♦ Company Policy (HR, Safety, and Others)
♦ Environment Policy
♦ Kaizen Policy
♦ R&R Policy
♦ IMS/QMS/OH&SMS/EMS/En.MS Certificates
♦ IT Policy
DOJO 2: Safety DOJO
Objective :
♦ Objective of Safety Dojo is “Prioritizing Safety for All Employees”
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 Senses DOJO
Objective :
♦ Standardize human senses for Actions.
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 11: Ergonomics DOJO
Objective :
♦ Enable employee to reduce fatigue for better productivity
Examples :
♦ Standing Posture Simulation
♦ Sitting Posture Simulation
♦ Material Lifting Posture Simulation
♦ Ankle Bend Simulator
♦ Elbow Bend Simulator
♦ aist 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
2.
Conduct Video Shoot
3.
Operational Analysis Table
4.
List Out ”Work” From Oat
5.
Refer Activity Sense Chart
6.
Create Simulation / Game
7.
Facilitate For Skill Training
8.
Measure Existing Skill Level
9.
Integrate Skill Trend Skill Matrix
10.
Reskill and Upskill Training
Advantages to create DOJO Training Center at your workplace
Over the time, the DOJO Training Center have contributed to a significant decrease in the quantity of quality issues.
1. Helps to activate senses versus activities
2. Build a safety workplace
3. Introduces the idea of error prevention
4. Generating reliable results
5. Gaining insight into productivity
6. Raises staff satisfaction
Process Specific DOJO For Industries
- Part loading to the fixture
- Edge burr removal
- Pasting logo sticker on fuel tank
- 90 degree Scanly plug assembly
- Single Person Multiple Machine Sequence Mapping Cycle Time Mapping Activity Mapping (Unload, Deburr, Checking)
- Orientation & Clamping
- Tube Bending
- Furnace Brazing
- Pointer Assembly
- Curvilinear welding for seam Welding
- Coil Placement on Conveyor
- Brazing_2 (With Input Control)
- Coupler / Nipple / Nozzle Fitting & Removal
- HLD Checking
- Hair Pin Insertion
- Screw Handling Ambidexterity
- Screw Handling Ambidexterity with Tightening
- Belt fixing for lifting of Stack of Steel Sheet
- Hinge welding DOJO in Bending Machine
- Part to Product Matching – Hinge to Doors Matching (Mix & Match Game)
- Lock Box selection & alignment of Lock Mode
- Projection Welding Points
- Inspection of Salvagnini output as per SOP Document
- More than 2400mm -material up & down side sticker pasting
- Burr Identification DOJO & Grinding DOJO
- Correct placement of Lock Box in spot welding section
- Manual checking of Gaps of Visual Panel
- Touch Sense DOJO – Rotation Angle Sensing
- Touch Sense DOJO – Pressure Application Sensing
- Hand Eye Coordination Game(Bi-Colour)
- Mechanical Screening & Crushing System
- Centrifugal Pump Test RIG
- Kaizen Eye & Kaizen Technique
- Process Optimisation DOJO
- Mechanical construction of rotatory dryer.
- Fluid Coupling
- Shaft Alignment Kit
- Enameling DOJO
- Assembly: Flame Direction and Focus
- Wax Setting: stone Identification
- Noise Protection Model and describe the difference between with and without Ear Muff
- Assembly : Twizer Handling for Surai Alignment
- Flame Direction And Focus
- Twizer handling For Surai
- Stone handling(Pick speed)
- Setting Stone Identification
- Design Sorting Left Right
- Ambidexterity – 4 Diff Colour balls touch the mark on the small conveyor belt & touch the respective color bin
- Blind Box 100 Pc Segregation Challenge A : 10 Types Material : Touch & Seeing Sense
- Silver Sorting – Pictorial (30 sets of picture reading coins)
- Dross Removal Process Simulator (Thermocol Balls Floating on Water and Shovel For Removal of TB)
- Mixing & Rubbling (without touching the refractory hearth and side walls) – Game with 1 ” Tballs
- Metal Loss : Skimming Hand Accuracy
- Metal Loss Reduction : Caster & Launder Gap Difference Mapping Game
- Male Female Cone Match with actual Tap Holes of 5 different sizes
- Piercing: Set Up Alignment
- Oiling : Dual Fit
- Oiling : Rod Breakage Reduction
- Delivery Process: Picking SOP Training
- Packaging : Pin Missing
- Packaging : SOP Training
- Hand safety stimulator (Rolling Machine)
- Safety shoe simulator
- Head safety simulator (Helmet)
- Safe walking speed simulator
- Waste management physical model
- Safety DOJO PPE matrix process wise
- DOJO plant layout (Emergency Evacuation Plan)
- Safety DOJO fire triangle
- Battery Safety During Charging & Discharging
- Eye Safety Simulator (Welding, Soldering & Object Impact)
- Touch Sense – Blind Box Diff Transistors Sensing
- Touch Sense – Blind Box Sensing ( IC, Resistors, Capacitors)
- Touch Sense – Air Blow Sensing (Motor Fan, ICs)
- Touch Sense – Heat Sensing (Motor and Controller)
- Eye (Seeing) Sense – Colour Code vs Specs Matching
- Hand Eye Cord – Different Shape Terminal Socket Fitting
- Hearing Sense – Electric Motor Vibration Sensing
- Smelling Sense – Battery Chemical Smell
- Motor & Bearing Maintenance ( Repair and Replace)
- Battery Leakage Maintenance (Rusting and Degradation)
- Wiring Harness Maintenance
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.
To get a copy of the DOJO Manual, List of Equipment, Simulation, DOJO Room Layout
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-square-meter area. Developed a 3D simulation and process flow design validated with the management team. The roles and responsibilities of the team were developed, and TMS onsite resources 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 Training Center setup 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 or Dojo Consultants charted a One – Month project plan for DOJO Training Center Set-Up in 2500 Sq. Meter area. Developed SOPs and documentation of the DOJO training strategy. Implemented “DOJO Strategy Manual” including DOJO Training 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
Our Clients
Complete Overview of Dojo in Manufacturing : Download E-book Now
Gallery
Appreciation Letters from Client
Testimonials
FAQs
What is the minimum space required for DOJO to be setup?
It’s astonishing to know that The DOJO Room can be Setup even without any use of space by using VR (Virtual Reality) in which no physical space is required.
What is the importance of safety DOJO In any manufacturing industry?
As we know safety standards are most important during the manufacturing process to be done and in spite of being aware that person involved in the process gets harmed physically for protection and awareness of safety DOJO is required.
What are the two scopes of DOJO provided by Tetrahedron?
SCOPE 1-
DOJO Center Consulting: For those Industries who are starting from the scratch and looking for A to Z Activities.
SCOPE 2-
Who are clear with the DOJO simulation & displays requirement and just looking for physical simulations.
What is DOJO 2.0?
DOJO 2.0 refers to an enhanced training center focused on process-specific on-the-floor training. It helps improve employees’ skills through real-time troubleshooting, process knowledge sharing, and awareness building related to problem-solving and safety.
What is 5 senses DOJO?
It is used to give training to a person for the use of senses involved in that particular manufacturing process so named as Sense DOJO. Like if any machining process uses hand and eye coordination.
What will be the duration of any DOJO project?
The tentative timeline of project is 45-60 days, but it may vary depending upon the process criticality required for simulations to be made.
How can we setup the DOJO training room?
Tetrahedron setup the DOJO training room by developing concepts of Know my company with various other concepts so that the person involved in any process gets to know about company morals and his CSR.
What is provided under maintenance DOJO?
| Critical Toolings |
| Tool Setting Process |
| TPM Pillar Description ( If applicable) |
| Electrical+Mechanical Maintenance LOTO, |
| LOTO Implementation Video |
| CLIT /Daily Machine Inspection Sheet (Cleaning, Lubrication, Inspection & Tightening) |
| Preventive Maint.- Flow Chart |
| Predective Maint.-Flowchart |