This document outlines the content and setup of mini training dojos or modules. It includes dojos on company overview, safety, 5 senses, product, production rules, quality, process, and maintenance. Each dojo contains virtual and practical learning representations and focuses on key topics through displays, stations, and equipment. The dojos aim to provide hands-on learning experiences to supplement virtual training.

1. Mini DOJOContent
S.No. DojoSteps Content
Representation
Virtual (On
screenorDisplay)
Practical
1 CompanyOverview
CompanyVision , Mission √
PlantLocations √
Major Customers √
OrganizationChart √
2. Safety Dojo
PPE’sthroughMannequin √
Fire extinguisher practice √
EmergencyEvacuation Plan √
Safety Videos (PPE’s, fire extinguisher, Work onHeight) √
3. 5 SensesDojo
Typesof Senses √
Different sensespracticestation √
4. Product Dojo
Products & its childParts √
Product Application √ √
Identification of similar lookingproducts √

2. Mini DOJOContent
S.No. DojoSteps Content
Representation
Virtual (Onscreen
or Display)
Practical
5. Production RuleDojo
4M Change& AbnormalityHandling √
ProcessCheck sheets √
Material Handling √
ShopFloor Do’s& Don'ts etc. √
6. Quality Dojo
PDIStation √
Quality Defects(Defect Gallery √
Measuring Instrument & Gaugingpractice √ √
7. Process Dojo
ProcessFlow & Process Video √
Deflashing station, torqueing station or Practical station asperprocess √
Different RawMaterial √
Mould or DiePart √
8. Maintenance Dojo
Maintenance Checksheet& procedure √
Maintenance Tools √
CLITsystem √

3. Scree
n
(0.81mtr.)
QualityDojo
(1.83mtr.)
ProcessDojo
(2.75 mtr.)
ProductDojo
(1.37 mtr.)
5 sensesDojo
(1.37 mtr.)
Safety
(1.14mtr.)
4.57 mtr. (15ft.)
Entrance
(0.91 mtr.)
Compan
y
Overvie
w
Productio
n
Rules
Maintenance
MiniDOJOLayout
3.04mtr.(10ft.)

4. CompanyOverview
Vision,Mission,CoreValues PlantLocations& Major Customers
S.No. Content
Represen
tation
1. Company
Vision, Mission
Audio
Visual
2. Company
Policies–
Quality ,Safety
3. Company
Organizatio
n Structure
4. Customers
5. Manufacturin
g Location

5. SafetyDojo
EmergencyEvacuation
PPE’s&Its
application
FireExtinguisher
S.No. Content Representation Cost
1. PPE’s Mannequin Rs.5500
2. Fire Extinguisher (2Kg)with work
instruction
Actual FireExtinguisher Rs.2500
3. PPE’svideo, Fire extinguisher video,
Emergency Evacuation
Audio Visual --
Total Rs.8000
FireExtinguisher& PPEvideo
(Virtual Learning– Screen)

6. Different sizeNut
segregation(Touch)
BlindBox Flash, WithoutFlash
(Touch)
S.No. Content Representation Cost
1 Table Actual Parts on table Rs.3000
2. Blind box (2Nos.) Rs.800
3. 5 SensesBoard Rs.200
Total Rs.4000
SimilarLookingParts(Sight)
5 SensesDojo
5 SensesBoard
Different sheetthickness:
Touch

7. DOJOModules Content Representation Cost
Machining
1. Old & FreshOil , coolant difference (Smell & color)
2. Part with or without burr , different surfaceroughness part,
scratch& without scratchpart , Ok& tight thread or dia (Touch) Physicalparts with bins
3. Minor porosity identification(sight)
5 SensesDojo
(Senses
actually used
in shopfloor)
Sheetmetal & Weld
1. Blanks of different sheet thickness , Sampleswith burr & without
burr, Sampleswith spatter & without spatter (Touch)
Physicalparts with Bins TableCost&
BinsCost: Rs.
40002. Defective samples, similar looking parts(Sight)
3. Metal & Wooden Hammer (Noise)
1. Looseor tight fitment ofparts samples, Different sizescrews
segregation , OK& NGtorquesense
Parts & torquewrench
2. Pegboard assy.With time
Wooden board with drilled
holes & sticks
3. Memory games: to join exploded parts of companylogo
4. 5Sgames
Mini DOJOmodule : 5Senses

8. ProductDojo
ProductGallery ProductApplication
ProductChildParts SimilarLookingPart S.No. Content Representation Cost
1. Table Rs.4000
2. Board Rs.1000
3. Part Application Actual Part/ AVor
Display
Total Rs.5000
ProductApplication

9. WorkInstruction& Checksheets Material HandlingTags S.No. Content Representa
tion
Cost
1. ShopFloorRules,
4M change
ProcessCheck
sheet,Tags,STOP
CALLWAIT
AudioVisual --
2. Material Handling
Bins
Actual Bins Rs.1500
Total Rs.1500
ProductionRule Dojo
4M Change AbnormalityHandling Material HandlingBinsShopFloorRules

10. p
QualityDojO
PDIStation& Poissontest DefectGallery
Content
InstrumentDisplay
Representation
Cost
1. BoardforDefect
Gallery
Actual Defectivepart Rs.1500
2. PDIStation Actual Rs.4500
3. Instrument & Quality
documentsprintout
Display & AudioVisual Rs.500
4. Gauging Practice Obsoletemodelgauge --
Total Rs.6500
Gauging

11. ProcessDojo
Mould & Its partsexplanation
Different Rawmaterial
1. Deflashing
station
Actual station Rs.4000
2. Old Die(Scrap) Actual Die Rs.2000
3. ProcessCheck
sheetprintout
Display Rs.500
4. ProcessVideo Audio Video
Total Rs.6500
DeflashingPracticeStation
Injection Molding
(video onscreen)
S.N
o. Content
Represen
ta tion
Cost

12. DOJOModules Content Representation Cost
ProcessDojo
Sheetmetal & Weld
1. MIG welding working module online MIG welding machine
2. Spot welding set-up(Dummy) Spot welding machine(Dummy) Rs8000
3. Dummy presswith input/output &safety curtains Dummy Press Rs.12000
4. Processflow with out put (Blanking, Piercing , Draw , welding etc.) ----
5. Grinder for burrremoval Grinder with parts Rs.3000
6. Tip Dressing practicestation
7. Distortion or bend removalpractice Hammer & Fixture
Machining
1. Old machining fixture with input & output Old machining fixture
2. Small Drilling & Tappingmachine Drill machine Rs15000
3. Filing practice after fettling &deburring File & table
4. ProcessFlow with processwise output &tools Tools,Processwise samples
5. Old Die withoutput for die parts understanding Old die
---
---
Mini DOJOmodule : ProcessDojo

13. MaintenanceToolDisplay
Maintenance Dojo
Typesof Maintenance MaintenanceProcedure& Checksheet
CLITSystem
Maintenance Tool Display Type of Maintenance Maintenance procedure & check sheet
S.No. Content Representation
1. Maintenance Tools
Audio Visual
2. Typesof maintenance
3.
CLITconcept
4. Maintenance procedure & check
sheet
CLIT System