Small dojo concept for reference-converted
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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.
Small dojo concept for reference-converted
- 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