The document discusses DOJO training, which is an offline practical training concept used to train new and existing employees. It involves a systematic 8 step process conducted in a simulated work environment. The steps include safety training, behavioral training, product knowledge training, production rule training, and process training. Trainees learn skills through simulators and practice before working on the actual shop floor under supervision. The goal is to reduce accidents and defects by ensuring employees are thoroughly trained and ready for their job responsibilities through this immersive offline practical training approach.

1. DOJO Training Concept

2. DOJO is a Japanese word
“a hall or place for immersive learning or meditation “
also used for a place in which judo and other martial arts are
practiced offline.
“DOJO” meaning

3. DOJO Training – “Offline Practical Training”
 New manpower : Off the Job training & practice session to new manpower before
deployment on shop floor.
 Existing manpower : To improve Quality sensitization, skills & multiskilling
Classroom training
(knowledge)
Offline training
(skill)
On Job Training
(under supervision)
DOJO

4. Systematic approach – 8 Step Process

5. Step- 2 (Safety DOJO)
# Usage of PPE & First aid
# Emergency route details / Fire detection
# Simulators - safety shoes / soft shoes
# Hot objects, weight (mass) impact etc.
# LOTO concept etc.
Step- 1 (Company overview)
# Dressing sense - cap ,shoes, ID card
# Plant layout
# Company policy & quality policy
# Company vision & mission
# Customer expectations – Zero Defect Target
etc.
Systematic approach – 8 Step Process
Target – ZERO accident
simulator – it can be
demonstrated as if we put
potato in soft shoes then
due to heavy weight,
Potato will crush else in
safety shoe, it will not
damage . Same concept is
applicable on individual
foot.

6. Step- 3 (Behavioral & 5 Senses DOJO)
# 5 Sense usage at work area
# Hands synchronization practice - TAKT
time achievement (simulators)
# Part miss condition /noise test/hot object
# Printing miss/ ratchet movement etc.
Step- 4 (Product knowledge)
# Practical explanation of product - Fit &
Functionality
# Customer & vehicle names
# Technical details - impact on end user in
case of failure etc.
Systematic approach – 8 Step Process

7. Step- 5 (Production rules)
# 4 M change control & monitoring
# Do's & Don't rules at shop floor
# Stop, Call, Wait concept
# Set up change over & work standardization
# Material handling & FIFO
# Calibrated instruments to be used etc.
Systematic approach – 8 Step Process

8. Step 6 – Process DOJO
b) Past defects history :-
c) Internal rejection study :-
a) Critical stations identification :-
• Maru A / Functional Process
• End of Line Testers
• PDI
• High Skill Level requirement
• Internal Engg/ Prodn. recommendation
S.N. Part No/
Name
Problem
details
Root
cause
1
35xxx / Oil
Comp. Assy.
Leakage
issue
Process D –
Fixture issue
Process mapping :-
based on study, critical processes to be identified & same
will be replicated in “DOJO Training Center “ for offline
practice .
C
C
C

9. Step 7 – Quality DOJO
# Measurement instruments & techniques (with practice)
# Defect gallery- OK/NG identification & practice
# Understanding of similar looking parts
# Checking fixture & gauge usage
# Calibration of Instruments
# Rework /rejection – control /correction / disposition etc.
Defect gallery :-

10. Systematic approach – 8 Step Process
Step- 8 (Maintenance DOJO)
# Major machine spares / tools used
# Pressure circuit
# CLIT concept (Cleaning, Lubrication,
Inspection & Tightening) etc.

11. Post DOJO Training - evaluation
Theoretical & Practical evaluation both to be done
example

12. OJT – new operator after DOJO training
Operator Observance system to be introduced

13. Skill mapping
Skill mapping w.r.to process category to be maintained

14. Process Vs defined skilled manpower
simple/
beginner station
critical station
new associate
after training
new associate + shop
floor experience
skilled associate
specialized process
1
specialized process
2
retraining to be
done
Deployment on Shop Floor

15. DOJO implementation – micro activity plan
S
No
Activity Mar’18 Apr’18 May’18 Jun’18 Jul’18
1 CFT formation
2 Vendor awareness
(Training session & benchmarking visits)
3
Planning based on process
mapping & methodology
requirements
4
DOJO room location & layout
finalization
5 Facility procurement / Installation
6
Training curriculum & modules
preparation
7 DOJO trainer Identification
8 Management review & feedback
9 Improvement based on feedback
10
Final review by management &
MSIL Team
11 Start of Training
reference

16. Thank You