Small dojo concept for reference-converted

A small training center for new comers or new joining

1. Mini DOJO Content S.No. Dojo Steps Content Representation Virtual (On screen or Display) Practical 1 Company Overview Company Vision , Mission √ Plant Locations √ Major Customers √ Organization Chart √ 2. Safety Dojo PPE’s through Mannequin √ Fire extinguisher practice √ Emergency Evacuation Plan √ Safety Videos (PPE’s , fire extinguisher, Work on Height) √ 3. 5 Senses Dojo Types of Senses √ Different senses practice station √ 4. Product Dojo Products & its child Parts √ Product Application √ √ Identification of similar looking products √

2. Mini DOJO Content S.No. Dojo Steps Content Representation Virtual (On screen or Display) Practical 5. Production Rule Dojo 4M Change & Abnormality Handling √ Process Check sheets √ Material Handling √ Shop Floor Do’s & Don'ts etc. √ 6. Quality Dojo PDI Station √ Quality Defects (Defect Gallery √ Measuring Instrument & Gauging practice √ √ 7. Process Dojo Process Flow & Process Video √ Deflashing station, torqueing station or Practical station as per process √ Different Raw Material √ Mould or Die Part √ 8. Maintenance Dojo Maintenance Checksheet & procedure √ Maintenance Tools √ CLIT system √

3. S c r e e n (0.81 mtr.) Quality Dojo (1.83 mtr.) Process Dojo (2.75 mtr.) Product Dojo (1.37 mtr.) 5 senses Dojo (1.37 mtr.) Safety (1.14 mtr.) 4.57 mtr. (15 ft.) Entrance (0.91 mtr.) Compa n y O v e r vi e w P r oduction Rules Maintenance Mini DOJO Layout 3.04 mtr. (10 ft.)

4. Company Overview Vision, Mission, Core Values Plant Locations & Major Customers S.No. Content Represen tation 1. Company Vision, Mission Audio Visual 2. Company Policies – Quality , Safety 3. Company O r g a n i z a tion Structure 4. Customers 5. Ma nu f a c t u ring Location

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

6. Different size Nut segregation (Touch) Blind Box Flash , Without Flash (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 Similar Looking Parts (Sight) 5 Senses Dojo 5 Senses Board Different sheet thickness : Touch

7. 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 (Senses actually used in shop floor) Sheet metal & Weld 1. Blanks of different sheet thickness , Samples with burr & without burr, Samples with spatter & without spatter (Touch) Physical parts with Bins Table Cost & Bins Cost : Rs. 4000 2. Defective samples , similar looking parts (Sight) 3. Metal & Wooden Hammer (Noise) 1. Loose or tight fitment of parts samples, Different size screws segregation , OK & NG torque sense Parts & torque wrench 2. Peg board assy. With time Wooden board with drilled holes & sticks 3. Memory games : to join exploded parts of company logo 4. 5S games Mini DOJO module : 5 Senses

8. Product Dojo Product Gallery Product Application Product Child Parts Similar Looking Part S.No. Content Representation Cost 1. Table Rs. 4000 2. Board Rs. 1000 3. Part Application Actual Part/ AV or Display Total Rs. 5000 Product Application

9. Work Instruction & Check sheets Material Handling Tags S.N o . Content R e p re se n t a tion Co s t 1 . Shop Floor Rules, 4M change Process Check sheet, Tags, STOP CALL WAIT Audio Visual -- 2. Material Handling Bins Actual Bins Rs .1500 T o t al Rs. 1500 Production Rule Dojo 4M Change Abnormality Handling Material Handling Bins Shop Floor Rules

10. p Quality Doj O PDI Station & Poisson test Defect Gallery Content Instrument Dis play Representation Cost 1. Board for Defect Gallery Actual Defective part Rs. 1500 2. PDI Station Actual Rs .4500 3. Instrument & Quality documents printout Display & Audio Visual Rs. 500 4. Gauging Practice Obsolete model gauge -- Total Rs. 6500 Gauging

11. Process Dojo Mould & Its parts explanation Different Raw material 1. Deflashing station Actual station Rs. 4000 2. Old Die (Scrap) Actual Die Rs. 2000 3. Process Check sheet printout Display Rs. 500 4. Process Video Audio Video Total Rs. 6500 Deflashing Practice Station Injection Molding (video on screen) S.N o. Content R ep r ese n t a tion Cost

12. DOJO Modules Content Representation Cost Process Dojo 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 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 5. Old Die with output for die parts understanding Old die --- --- Mini DOJO module : Process Dojo

13. Maintenance Tool Display Maintenance Dojo Types of Maintenance Maintenance Procedure & Check sheet CLIT System Maintenance Tool Display Type of Maintenance Maintenance procedure & check sheet S.No. Content Representation 1. Maintenance Tools Audio Visual 2. Types of maintenance 3. CLIT concept 4. Maintenance procedure & check sheet CLIT System