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DOJO Center Set Up

©Tetrahedron, V-1.0

Addressing Shop Floor’s Critical Activity by


Designing Process Specific DOJO
Why DOJO
Customer Satisfaction (SPQC) 12
1
2

Employee Skill
11 3
12 Level
Internal Waste / Cost Reduction 10 DOJO 4
Sequence
9 5

8 6
Sustenance / Internal PC 7

Tetrahedron helps Translate the Essential Skills Required in Manufacturing Process to


Activity Based DOJO. These skills help an organisation for achieving customer
satisfaction, internal cost reduction and sustenance of organisational capability
Skilling Right Skilling Re Skilling

• For New Operators • Focus towards exact • For Up Gradation of all


process for skilling operators

Manufacturing Excellence Training & Skill Development Automation & Industry 4.0
01 - Know My Company 05 - Process and Machine Matrix
1. Company Profile 1. Critical Machine Simulation

Different DOJO Simulations


2. Company Vision, Mission & value 2. Part Criticality Matrix
3. Company Funders and History 3. Start ‒ Stop ‒ Emergency Stop
4. Company Footprint & Product Portfolio
4. Electrical Part & Electronic Part
5. Customer Base & Geography Coverage
6. Research & Development 5. Pneumatic Part & Hydraulic Part
7. CSR Activities 6. Fasteners & Mechanical Part
8. Company Policy (HR, Safety and Others)
06 - Production DOJO
02 - Safety DOJO
Know Your Company 1. Abnormality Matrix
1. Safety Pledge 2. 4M Change Matrix
1 2. Safety Sign Colour Simulator (4 Colours) 3. Work Instruction
4. Shop Floor Do s Don t
Innovation 12 2 Safety 3.
4.
Fire Extinguisher application
Fire Hydrant Application
5. Visual Management

5. Fire Triangle
6. PPE Matrix & PPE Usage 07 - Quality DOJO
7. Falling from Height simulator ( Harness)
1. Gauge Awareness
Ergonomics 11 3 Product
8.
9.
Safety Shoe simulator
Hand Safety Simulator
2. Best Practices of Using Gauges
3. Defect Gallery
10. Head Safety Simulator ( Helmet)
4. Poka-Yoke
11. Eye Wash simulator
12. Safe walking speed Simulator
13. Fire Safety Board 08 - Maintenance DOJO

Certification 10 12 Level DOJO 4


14.
15.
Electric Safety Board
Dust Mask simulation
1. Critical Tooling's & Tool setting video
5 Senses 16. Nose (Smell) DOJO
2. TPM Pillar Description ( If applicable)

Sequence 17.
18.
Noise Protection Simulation
Waste Management
3.
4.
Electrical Maintenance & LOTO,
Mechanical Maintenance & LOTO
5. Hydraulics & Pneumatic DOJO Simulation
19. Gas Cylinder Safe Handling
6. Gear Functioning Simulation
20. CPR and First Aid
21. Emergency Exit Simulation (VR Base)

OJT & Test 9 5 Process


09 - OJT & 10 - Certification
03 - Know My Company 1. Training KPIs
2. Visual SOPs
1. Product Range & Product Usage (Real Sample)
3. Certification
2. Product Usage (Simulation)

Maintenance 8 6 Production
3.
4.
Part ‒ Product Matrix
Criticality of Product 11 ‒ Ergo DOJO
7 5.
6.
Similar Product in Market
Simulation (Virtual Reality Base) 1. Standing & Sitting Posture Simulation

Quality 2.
3.
Material Lifting posture simulation
Ankle Bend, Elbow Bend, Waist Bend
04 - 5 Senses DOJO 4. Ergonomics Best Practices Videos
1. Touch Sense DOJO ‒ 8 Variants
2. Hand Eye Coordination ‒ 15 Variants 12 ‒ Inno DOJO
3. Hearing Sense DOJO ‒ 4 Variants
4. Seeing Sense DOJO ‒ 6 Variants 1. Low Cost Automation Simulation
5. Black Box Exercise (Touch Sense) ‒ 6 Variants 2. Kara-Kuri Material Handling System
6. Vibration Sensing DOJO
3. SCAMPER Technique
7. Heat Sensing DOJO
4. Kaizen demonstration
8. Smelling Sense DOJO ‒ 5 Type Smell

Manufacturing Excellence Training & Skill Development Automation & Industry 4.0
DOJO List
01 - Know My Company 04 - 5 Senses DOJO 06 - Production DOJO
1. Company Profile 1. Sub Conscious Mind ‒ Time Count DOJO 1. Abnormality Matrix
2. Company Vision, Mission & value 2. Touch Sense ‒ Blind Box Weight Sensing 2. 4M Change Matrix
3. Company Funders and History 3. Touch Sense ‒ Blind Box Size Sensing 3. Work Instruction
4. Touch Sense ‒ Blind Box Shape Sensing 4. Shop Floor Do s Don t
4. Company Footprint & Product Portfolio
5. Touch Sense ‒ Blind Box Similar Part Sensing 5. Visual Management
5. Customer Base & Geography Coverage
6. Touch Sense ‒ Blind Box Diff Part Sensing
6. Research & Development 7. Touch Sense ‒ Rotation Angle Sensing
7. CSR Activities 07 - Quality DOJO
8. Touch Sense ‒ Length Sensing
8. Company Policy (HR, Safety and Others) 9. Touch Sense ‒ Torque Sensing 1. Gauge Awareness
10. Touch Sense ‒ Heat Sensing 2. Best Practices of Using Gauges
11. Ambidexterity ‒ Limb Speed Comparison 3. Defect Gallery
12. Ambidexterity ‒ 2 Hand 2 Bin Same Part 4. Poka-Yoke
02 - Safety DOJO 13. Ambidexterity ‒ 2 Hand 2 Bin Diff Part
1. Safety Pledge 14. Ambidexterity ‒ 2 Same Activity
15. Ambidexterity ‒ 2 Similar Activity 08 - Maintenance DOJO
2. Safety Sign Colour Simulator (4 Colours)
16. Ambidexterity ‒ 2 Different Activity
3. Fire Extinguisher application 17. Hand Eye Cord ‒ Electric Wire Test Set 1. Critical Tooling's & Tool setting video
4. Fire Hydrant Application 18. Hand Eye Cord ‒ Same Size Pin Set 2. TPM Pillar Description ( If applicable)
5. Fire Triangle 19. Hand Eye Cord ‒ Diff Shape Pin Set 3. Electrical Maintenance & LOTO,
6. PPE Matrix & PPE Usage 20. Hand Eye Cord ‒ Reverse Colour Pin Set 4. Mechanical Maintenance & LOTO
7. Falling from Height simulator ( Harness) 21. Hand Eye Cord - Reverse Board Pin Set 5. Hydraulics DOJO Simulation
8. Safety Shoe simulator 22. Hand Eye Cord ‒ Coloured PIN Set 6. Pneumatic DOJO Simulation
9. Hand Safety Simulator 23. Hand Eye Cord ‒ 6 Angle Screw Set 7. Gear Functioning Simulation
24. Hand Eye Cord ‒ 6 Angle Bolt Set
10. Head Safety Simulator ( Helmet)
25. Eye ( Seeing) Sense ‒ Select The Right Fit Tool
11. Eye Wash simulator 26. Hearing Sense ‒ 6 Set Same Decibel Sound 09 - OJT & 10 - Certification
12. Safe walking speed Simulator 27. Hearing Sense ‒ 6 Set Diff Decibel Sound
13. Fire Safety Board 28. Hearing Sense ‒ Gear Knock Sound 1. Training KPIs
14. Electric Safety Board 29. Hearing Sense ‒ Vibration Sensing 2. Visual SOPs
15. Dust Mask simulation 30. Smelling Sense ‒ Fuel Smell 3. Certification
16. Nose (Smell) DOJO 31. Smelling Sense ‒ Chemical Smell
17. Noise Protection Simulation 32. Smelling Sense ‒ Electric Wire Burning Smell 11 ‒ Ergo DOJO
33. Closed Eye Simulation ‒ Assy Process Seq
18. Waste Management
19. Gas Cylinder Safe Handling 1. Standing Posture Simulation
20. CPR and First Aid 2. Sitting Posture Simulation
21. Emergency Exit Simulation (VR Base)
05 - Process and Machine Matrix 3. Material Lifting posture simulation
4. Ankle Bend Simulation
1. Critical Machine Simulation 5. Elbow Bend Simulation
2. Part Criticality Matrix 6. Waist Bend Simulation
03 - Know My Company 3. Start ‒ Stop ‒ Emergency Stop 7. Ergonomics Best Practices Videos
4. Electrical Part
1. Product Range & Usage (Real Sample)
2. Product Usage (Simulation)
5. Electronic Part 12 ‒ Inno DOJO
3. Part ‒ Product Matrix 6. Pneumatic Part
1. Low Cost Automation Simulation
4. Criticality of Product 7. Hydraulic Part 2. Kara-Kuri Material Handling System
5. Similar Product in Market 8. Fasteners 3. SCAMPER Technique
6. Simulation (Virtual Reality Base) 9. Mechanical Part 4. Kaizen demonstration

Manufacturing Excellence Training & Skill Development Automation & Industry 4.0