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Dojo - Training and Skill Development PPT
- 1. “Training & SkillDevelopment“ DOJO Training Center
- 2. Class Room Training OnJob Training- Trainee Pilot Off Line Training Simulator Analogy - Pilot Training
- 3. DOJO On JobTraining DOJO Training : Concept Learning in Class room sessions (Knowledge) Practice on Offline Practice station (Skill) Under Supervision
- 4. Key Focus Areas Manpower Planning& recruitment - Manpower Recruitment should be done in batches so that entire batch can undergo DOJO Training at One Time Joining of candidates in batches Manpower planning as per estimated gap On Job Training (under supervision) Manpower recruitment DOJO Training Skill EvaluationPass Fail
- 5. Key Focus Areas - ManpowerRecruitment should be done in batches so that entire batch can undergo DOJO Training at One Time Day-1 Day-2 Day-3 Day-4 Day-5 Day-6 Day-7 Shop Floor Monday Tuesday Wednesday Thursday Friday Saturday Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sunday Batch -02 Batch-01 Batch -01 Batch -02 Shop Floor Before: No fixed days for Intake of Associate After : Days Fixed for intake of Associate. Bench Strength maintained by increasing Batch size.
- 6. All manpower deployedat shop floor, should be imparted right knowledge & skill. New Manpower : An Initial Training to understand : Shop floor rules How to do correct job & Processes involved Existing Manpower : to enhance their : Skill Level Quality Sensitization DOJO Training : Objective :
- 7. DOJO Center – Implementation 56 166 90 AllVendor Plants 2016-17 2017-18 2018-19 (till Nov’18) 2019-20 All Vendors should have DOJOcenter by
- 8. DOJO Training –8 Modules
- 9. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO Maintenance DOJO 1 2 3 4 5 6 7 Evaluation 8 DOJO Training – 8 Modules
- 10. Objective : Awarenessabout the Organizational Vision, Mission, Core Values, Major Customers, Quality Policy & Customer expectations (ZERO Defect) Company Profile Vision Major Customer 1. Company Overview Core Values
- 11. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO 1 2 3 4 5 6 7 Evaluation 8 Maintenance DOJO DOJO Training – 8 Modules
- 12. PPE’s usage SafetySimulator 2. Safety DOJO Objective : Awareness about : Personal Protective Equipment (PPE’s) & usage Actions during emergency (Fire, Escape route) Safety Policy
- 13. Fire Safety LearningBoard 2. Safety DOJO Emergency Evacuation Plan
- 14. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO Maintenance DOJO 1 2 3 4 5 6 7 Evaluatio n 8 DOJO Training – 8 Modules
- 15. Objective : Developmentof Senses for improving Quality & Productivity Hand Eye coordination 3. Behavioral & 5 Sense DOJO
- 16. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO Maintenance DOJO 1 2 3 4 5 6 7 Evaluatio n 8 DOJO Training – 8 Modules
- 17. Objective : Todevelop awareness about Product , its Fitment & Functions Product – working model Product – Fit & Functionality 4. Product Knowledge DOJO Product identification
- 18. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO 1 2 3 4 5 6 7 Evaluatio n 8 Maintenance DOJO DOJO Training – 8 Modules
- 19. Objective : Awareness& Training of Production rules actually followed at shop floor STOP, CALL, WAIT concept 4 M Change Control Assembly Production Rules 5. Production Rules DOJO
- 20. Material Handling Rules FIFOConcept 5. Production Rules DOJO
- 21. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO Maintenance DOJO 1 2 3 4 5 6 7 Evaluatio n 8 DOJO Training – 8 Modules
- 22. 6. Process DOJO Objective :To give full training & skill for performing the process which he suppose to perform on actual shop floor, all the critical stations should be identified & training to be provided in DOJO . The below mentioned steps to be followed for finalization :- a) Critical Stations identification : b) Past Defects History : c) Internal Rejection Study : • Maru A / Functional Process • End of Line Testers • PDI • High Skill Level requirement • Internal Engg/ Production recommendation S.N. Part No/ Name Problem details Root cause 1 35xxx / Oil Comp. Assy. Leakage issue Process D – Fixture issue
- 23. Objective : Todevelop skill for performing the Critical Processes on actual shop floor Leak Testing Machining Process Soldering Process 6. Process DOJO Assembly Process
- 24. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Quality DOJO Maintenance DOJO 1 2 3 4 5 6 Process DOJO 7 Evaluation 8 DOJO Training – 8 Modules
- 25. Objective : Toclarify OK/NG parts, Inspection Standard & Inspection Tools Defect Gallery Measurement Practice 7. Quality DOJO Defect Identification
- 26. 7. Quality DOJO SpecializedInspection - Pre GCA Practice Testing (Gauge Inspection)
- 27. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO Maintenance DOJO 1 2 3 4 5 6 7 Evaluation 8 DOJO Training – 8 Modules
- 28. Objective : Tounderstand basic Machine Maintenance checkpoints (CLIT) - Understanding of machine abnormalities & Leakage etc. 8. Maintenance DOJO
- 29. DOJO Training In-charge/ Subject Matter Expert - Preferably a dedicated Trainer/ Training In-charge should be deployed - Expert Trainers for Shop floor / other areas for specific Training Training In-charge Roles & Responsibilities Have Positive attitude, motivate the trainees Good communicator, able to engage trainees & keep the interest alive Should be aware about usage & importance of each facility available Develop Curriculum, take pre-test & ensure Timely completion of training Ensure 5S , discipline & safe operation Post training evaluation & Feedback gathering Subject Matter Experts (SME’s) Roles & Responsibilities Have good command on Technical Area Having hands on experience of Process – shop floor Can resolve queries asked by Trainees Develop Technical structure for training , prepare pre-test & Post Test requirement should explain clearly Do’s / Don’t of Processes Evaluate Trainee’s work area based on evaluation/ observation
- 30. - Day-wise curriculumwith required Technical topics to be made for New as well as Existing Manpower Curriculum
- 31. Company Overview Safety DOJO Behavioral& 5 Sense Product Knowledge Production Rules Process DOJO Quality DOJO Maintenance DOJO 1 2 3 4 5 6 7 Evaluatio n 8 DOJO Training – 8 Modules
- 32. Objective : Theoretical& Practical evaluation after DOJO Training completion Example Post Training Evaluation Theoretical Evaluation Practical Evaluation
- 33. Simple/beginner station Critical Station new Associate AfterTraining Experienced Associates + Critical Station Training Deployment on Shop Floor Skilled Associates Process 1 Process 2 retraining to be done
- 34. Improved Skill, Confidence& Morale of employees DOJO – Major Benefits Reduction in Man related defects Improvement in retention of employees Improvement in Rule Awareness & Adherence
- 35.