MINI DOJO KICK OFF & BENCHMARK VISIT

Agenda :- Mini Dojo Kick off meeting

Agenda : Mini Dojo Visit at M/s. Asian Spring, Faridabad

Attendees : MSIL Vendor Partners

Time Activity

10:00 ~ 10:05 hrs Welcome

10:05 ~ 10:15 hrs Address by MSIL Management

10:15 ~ 10:35 hrs “Mini Dojo concept explanation” by MSIL

10:35 ~ 10:45 hrs Experience sharing by SMR Team

10:45 ~ 11:30 hrs Demonstration of Mini Dojo on Shop-floor

11:30 ~ 11:50 hrs Tea break + Q&A Session

11:50 ~ 12:00 hrs Closing Remarks

Why MINI DOJO

77%
69%
54%
47%

Abnormality Document Change Education &

handling control Management Training

Education & Training system weak at 77 % Tier-2’s

Mini DOJO Concept & 8 Sections
Objective
Objective:-
To Strengthen Education & training system at Tier 2
vendors to achieve our mission towards ZD

Mini DOJO Proposed concept details:

Area Required
150 Square feet
(Approx.)

Investment
Rs.50,000/-
(Approx.)
Plastic Moulding, Sheet metal,
Category Machining, Electrical, Assembly,
Rubber moulding
Proposed Mini DOJO Layout (For reference)
Entrance
Process Dojo (0.91 mtr.)

Overview
Company
(2.75 mtr.)

Quality Dojo

Production
3.04 mtr. (10 ft.)

Rules
Screen
(0.81 mtr.)
(1.83 mtr.)

Maintenance
Product Dojo 5 senses Dojo Safety
(1.37 mtr.) (1.37 mtr.) (1.14 mtr.)

4.57 mtr. (15 ft.)

Mini DOJO Content
Representation
S. No. Dojo Steps Content Virtual Practi
(Screen / Display) cal
Company Vision , Mission √
Plant Locations √
1 Company Overview
Major Customers √
Organization Chart √
PPE’s through Mannequin √
Fire extinguisher types & how to use √ √
2. Safety Dojo
Emergency Evacuation Plan √
Safe rules Do’s & Don’t’s √
Types of Senses, WI & Evaluation form √
3. 5 Senses Dojo
Practice senses applicable √
Products & its child Parts √
Product Application in T1 Parts √ √
4. Product Dojo
Raw material
Identification of similar looking products √
Mini DOJO Content
Representation
S.No. Dojo Steps Content Virtual
Practical
(Screen / Display)
4M Change & Abnormality Handling (as per Vendor quality manual ) √
Process/Production Check sheets explanation & practice √
5. Production Rule Dojo
Material Handling ( NG /Ok Part identification, over flow ) √
Shop Floor Do’s & Don'ts etc. √
PDI Station having all basic requirements √
6. Quality Dojo Defects Gallery (Display of defective parts) √
Measuring Instrument & Gauging practice √ √
Process Flow & Process Video √
Hand on training on manual CTQ processes eg. Deflashing soldering √
7. Process Dojo
OPS check sheet , WI display/video √
Machine elements / Mould or Die Part ( Refer process Dojo slides ) √
Maintenance Checksheet & procedure √
8. Maintenance Dojo Maintenance Tools √
CLIT system √
Process Flow - Mini Dojo
New operator Joining

Day 1
General , Safety & Product
Dojo training

Production, Quality & 5 Senses

Day 2 Dojo training

RETRAINING
Process & Maintenance
Dojo training

Written Test
Day 3

If Marks NO
>=60%
YES Fail in
retraining

On Job Training (OJT)

Day 4 & 5
( Under supervision at production) Not suitable
 Dojo Training (Typical) Curriculum – Mini Dojo
Day Activity Time 9:00 -10:30 10:30 - 13:00 13:00 - 13:30 13:30 - 15:30 15:30 - 17:00

Content Joining Formalities Company Overview Safety Training Product Knowledge

Joining ,
Company Video on screen, PPE
Day-1 Overview, Safety Lunch Break Practical with actual
Method Discussion Form PPT & Video on screen application through
& Product products
mannequin
Knowledge

Place Dojo Room Dojo Room Dojo Room Dojo Room

Content 5 Senses Production Rule Quality Dojo

5 Senses, Quality
Day-2 & Production Lunch Break
Rule
Method Practical PPT on screen Practical

Place Dojo Room Dojo Room Dojo Room

Content Process Dojo Maintenance Dojo Evaluation

Process,
Day-3 Maintenance & Method Practical & Process Video Lunch Break Video & ppt. Test Paper
Evaluation
Place Dojo Room Dojo Room Dojo Room
Company Overview

Represen
S.No. Content
tation
1. Company
Vision, Mission
2. Company
Policies –
Quality , Safety
3. Company Audio
Organization Visual
Structure
4. Customers

5. Manufacturing
Location
Safety Dojo
PPE’s & Its Fire Extinguisher & PPE video
Fire Extinguisher Emergency Evacuation
application (Virtual Learning – Screen)

S.No. Content Representation Cost

1. PPE’s Mannequin Rs.5500
2. Fire Extinguisher (2Kg) with work Actual Fire Extinguisher Rs. 2500
instruction
3. PPE’s video, Fire extinguisher video, Audio Visual --
Emergency Evacuation

Total Rs. 8000

5 Senses Dojo
5 Senses Board Blind Box

Different sheet thickness :

Similar Looking Parts (Sight)
Touch
S.No. Content Representation Cost

1 Table Actual Parts on table Rs.3000

2. Blind box (2 Nos.) Rs.800

3. 5 Senses Board Rs. 200

Total Rs. 4000

Mini DOJO module : 5 Senses
DOJO Modules Content Representation Cost
Machining

1. Old & Fresh Oil , coolant difference (Smell & color)

2. Part with or without burr , different surface roughness part,

scratch & without scratch part , Ok & tight thread or dia (Touch) Physical parts with bins

3. Minor porosity identification (sight)

5 Senses Dojo Plastic Moulding

(Senses 1. Parting Line flash / without flash , War page deformation(Touch) Physical parts with Bins Table Cost &
2. Surface texture glossy / rough, sink mark, weld line , different raw Bins Cost : Rs.
actually used materials (sight) 4000
in shop floor) Assembly

1. Loose or tight fitment of parts samples, Different size screws

Parts & torque wrench
segregation , OK & NG torque sense

Wooden board with drilled

2. Peg board assy. With time
holes & sticks

3. Memory games : to join exploded parts of company logo

4. 5S games
Mini DOJO module : 5 Senses
DOJO Modules Content Representation Cost
Sheet metal & Weld

1. Blanks of different sheet thickness , Samples with burr & without

burr, Samples with spatter & without spatter (Touch)
Physical parts with Bins
2. Defective samples , similar looking parts (Sight)
5 Senses Dojo
3. Metal & Wooden Hammer (Noise) Parts & hammer Table Cost &
(Senses Bins Cost : Rs.
Rubber
4000
actually used
1. Cured & Over cured / under cured samples segregation, Samples
in shop floor) with & without flash (Touch)
Physical parts with Bins
2. Segregation of rubber moulding defects , similar looking parts
(sight)

3. Different compound smell (Nose)

Product Dojo
Product Gallery Product Application

1 1
4
2

4 3

Product Child Parts Raw material S.No. Content Representation Cost

1. Table Rs. 4000
2. Board Rs. 1000
3. Part Application Actual Part/ AV or
Display
Total Rs. 5000
Production Rule Dojo
Shop Floor Rules 4M Change Abnormality Handling Set-up part procedure &
process checksheet

Material Handling Bins & Tags 5S

S.No. Content Representa Cost
tion
1. Shop Floor Rules, Audio Visual --
4M change
Process Check
sheet, Tags, STOP
CALL WAIT

2. Material Handling Actual Bins Rs .1500

Bins

Total Rs. 1500

Quality Dojo
PDI Station & Poisson test Defect Gallery Instrument Display

Gauging S.No. Content Representation Cost

1. Board for Defect Actual Defective part Rs. 1500
Gallery
2. PDI Station Actual Rs .4500

3. Instrument & Quality Display & Audio Visual Rs. 500

documents printout
4. Gauging Practice Obsolete model gauge --

Total Rs. 6500

Process Dojo
Mould & Its parts explanation Chamfering & Deflashing Practice Station

Process flow Injection Molding S.N Representa

(video on screen) Content Cost
o. tion
1. Deflashing Actual station Rs. 4000
station
2. Old Die (Scrap) Actual Die Rs. 2000
3. Process Check Display Rs. 500
sheet printout
4. Process Video Audio Video

Total Rs. 6500

Mini DOJO module : Process Dojo
DOJO Modules Content Representation Cost
Sheet metal & Weld
1. MIG welding working module on line MIG welding machine
2. Spot welding set-up (Dummy) Spot welding machine (Dummy) Rs 8000
3. Dummy press with input/output & safety curtains Dummy Press Rs.12000
4. Process flow with out put (Blanking, Piercing , Draw , welding etc.) ----
5. Grinder for burr removal Grinder with parts Rs. 3000
6. Tip Dressing practice station
7. Distortion or bend removal practice Hammer & Fixture
Rubber
Process Dojo 1. De-flashing station for de-flashing practice & marking Table with WI Rs. 3000
2. Feeding template for setting of mould Feeding template set-up Rs 3000
3. Mandrel (Twisting or strip cutting) Obsolete mandrels ---
4. Old / obsolete model die with output for die parts understanding Old Dies with parts ----
Plastic Moulding
1. De flashing/ Gate Cutting station with heater Table & Heater Rs 5000
2. Old mould for mould knowledge , part ejection from mould
Old mould ---
practice, Releasing agent spray practice.
3. Different raw material knowledge Actual raw material ---
Mini DOJO module : Process Dojo
DOJO Modules Content Representation Cost
Machining

1. Old machining fixture with input & output Old machining fixture

2. Small Drilling & Tapping machine Drill machine Rs 15000

3. Filing practice after fettling & deburring File & table

4. Process Flow with process wise output & tools Tools, Process wise samples

Process Dojo 5. Old Die with output for die parts understanding Old die
Assembly

Table, Assembly fixture, Torque

1 Dismantling & assembly of complete parts w.r.t WI Gun , Pressing or stacking station, Rs 9000
basic assembly tools

Electrical

1. Soldering & Crimping process Soldering & Crimping station Rs 9000

Maintenance Dojo
Maintenance Tool Display Types of Maintenance Maintenance Procedure & Check sheet

S.No. Content Representation

CLIT System
1. Maintenance Tools

2. Types of maintenance

3. Audio Visual
CLIT concept

4. Maintenance procedure & check

sheet
Mini Dojo Cost
S.No. Steps Cost (Rs.)
Dojo 8 steps cost : Rs. 31,500/-
1 Company Overview (Audio Visual etc.) ---
2 Safety Dojo (Mannequin/Boards, Fire Ext) 8000
3 Product Dojo (Table / Board) 5000
4 Process Dojo (Old Mould/ Deflashing Station/ Display) 6500
5 5 Senses Dojo (Table / Bins) 4000
6 Quality Dojo (Board/ PDI station / Bins/ Displays) 6500
7 Production rule Dojo (Audio Visual / Material Handling Bins) 1500
8 Maintenance Dojo (Audio Visual) ---

Others Cost: Rs. 16,500/-

9 Screen / Monitor Cost 12,000
10 Chair Cost (4 Nos.) 4500

Total 48,000/-
Mini Dojo Guidance Handbook
MINI DOJO guidance manual chapters
• Mini DOJO training concept

• Company overview

• Safety DOJO

• 5 sense DOJO

• Product DOJO

• Production rule DOJO

• Process DOJO

• Quality DOJO

• Maintenance DOJO

• Training assessment

• DOJO effectiveness & utilization