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DOJO Training Center - Increasing Productivity of The Workforce
DOJO Training Center - Increasing Productivity of The Workforce
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DOJO OVERVIEW
A Dojo center is known for manufacturing companies
where newly hired team members can get professional
training and acclimate to take on their responsibility
effectively to work on the manufacturing shop floors. To
complete a particular task in a dojo center, he or she is
trained again and again with the help of replica
models/stimulators and mock-ups until they become
perfect at their task. Actual Shopfloor environment with
all the simulator & actual training environment for newly
hired workers who give confidence to the new operators
and give time-to-time guidance to correct them. After
taking training from the Dojo Training Center, a worker
feels more comfortable and confident on the shop floor
and performs his work better.
DOJO
The term 'Dojo' originates from Japan
and refers to a room or hall where
JUDO is practiced, while in Hindi it is
known as Akhada. It combines the
words 'do' meaning 'the way' or 'the
pursuit' and 'jo' meaning 'a place',
thus representing a 'place of the
pursuit'.
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The facility is equipped with state-of-the-art equipment and tools that
replicate the actual working conditions employees will encounter in
their roles. This allows them to familiarize themselves with the
equipment, practice using it, and gain confidence in their abilities. The
training center also provides a safe environment for employees to make
mistakes and learn from them without any negative consequences.
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CHAPTER 1: INTRODUCTION: THE EVOLUTION
OF DOJO LEA N M ANUFA C TURING
Over the past few years, the incorporation of lean manufacturing
principles into specialized training facilities called DOJO training centers
has represented a notable shift in how companies address employee
growth and ongoing enhancement. These centers function as interactive
learning spaces where employees can participate in practical training,
experimentation, and skill enhancement with the support of seasoned
facilitators.
In order to truly grasp the lean philosophy, one must have a deep and
unwavering interest in the nuances of the work. The Dojo provides an
environment where individuals can immerse themselves in the intricacies
of lean methodology, honing their skills and understanding through
hands-on practice and continuous learning. By emphasizing meticulous
actions, the Dojo ensures that learners develop a keen eye for detail and
a commitment to precision.
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CHAPTER 2: UNDERSTANDING THE DOJO TRAINING
METHOD
1. Experiential Learning:
The DOJO Training Method focuses on practical exercises, simulations,
and real-world problem-solving. Participants gain a deeper
understanding of lean manufacturing principles and develop directly
applicable skills.
2. Continuous Improvement:
The DOJO Training Method encourages participants to identify areas for
improvement, explore new concepts, collaborate with peers, and
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achieve gradual but significant enhancements in productivity, quality,
and efficiency.
3. Cross-Functional Collaboration:
DOJO training encourages cross-departmental collaboration, knowledge
sharing, diverse perspectives, and barrier removal. Participants gain
insights into organizational challenges and identify enhancement
opportunities.
6. Practical Application:
DOJO training bridges theory and practice, empowering participants to
apply lean principles and problem-solving methods to real-life
challenges.
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CHAPTER 3: CREATING A CULTURE OF
CONTINUOUS IMPROVEMENT W ITH DOJO
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3. Recognition and Rewards:
Recognizing and motivating employees for their contributions to
continuous improvement boosts positive work behaviors and
engagement. Businesses can praise employees who excel in DOJO
training sessions through verbal recognition, peer appreciation, and
tangible rewards like bonuses.
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C HAPTER 4: LEVEL OF SKILL MAPPING IN
DOJO C ENTRE
The workforce is divided into skill levels ranging from 0 to 4, each
representing a different level of expertise and experience. At Level 0,
we have new workers who are just starting their careers and have no
prior experience in the field. These individuals require guidance and
assistance to perform tasks effectively.
Moving up to Level 1, we find workers who have gained some basic skills
and knowledge but still require help and supervision to complete their
tasks. They are capable of performing their duties with assistance but
may not have the confidence or expertise to work independently.
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Finally, at Level 4, we have workers who have reached the pinnacle
of their field. These individuals have extensive knowledge and
experience, allowing them to not only excel in their own roles but also
train and mentor others. They are recognized as experts in their field
and are often sought after for their insights and guidance.
By dividing the workforce into these skill levels, organizations can better
understand the capabilities and potential of their employees. This
division allows for targeted training and development programs to help
individuals progress from one level to the next, ensuring a skilled and
competent workforce.
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C HAPTER 5: SENSES OF HUM AN BEING
5 SENSES
Meaning
In the context of workplace training, a dojo
serves as a dedicated learning center where
workers can hone their skills and knowledge.
Just like learning to ride a bike or drive a car,
mastering tasks in the workplace requires
practice, guidance, and repetition. The dojo
provides a structured environment for
employees to receive training tailored to their
specific roles and responsibilities
Touch
This sense allows us to feel physical
contact and pressure. It is involved in
activities like moving our limbs, picking
up and placing objects, sensing
vibrations, determining weight, lifting
things, measuring temperature, and
handling materials with different textures
and properties.
Sight
Vision enables us to see light and
distinguish shapes, colors, and spatial
relationships. It is crucial for activities
such as measuring dimensions,
observing marks or patterns, identifying
colors, and tracking the movement of
objects in our surroundings
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5 SENSES
Hearing
Auditory perception helps us detect
and interpret sound waves. Activities
involving hearing include recognizing
vibrations, identifying sounds caused by
friction (like gas exhaust or creaking),
understanding material interactions
(such as impacts or leaks)
Smell
Our sense of smell allows us to detect
airborne molecules and perceive odors.
Activities related to smell include
detecting chemicals, identifying
chemical leaks, sensing burning
materials (like fuel or substances),
detecting electrical sparks, recognizing
material decay, and perceiving
unpleasant or noxious smells.
Taste
While taste is not as frequently involved
in many activities, it helps us discern
flavors through the chemical receptors
on our tongues. However, taste is
primarily associated with eating and
drinking in most daily activities
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C HAPTER 6: AC TIVITY VS SENSES IN DOJO
Below is an example illustrating what a dojo is and how it helps
individuals in their learning process:
Imagine you're learning how to ride a bicycle for the first time. At the
beginning, it feels daunting and unfamiliar. You're constantly focusing on
balancing, pedaling, and steering, all while feeling a bit scared of falling
over. However, with practice and perseverance, you start to adapt. Your
senses become attuned to the movements and sensations of riding.
Eventually, you find yourself pedaling effortlessly, confidently
navigating turns, and even riding with one hand.
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workplace requires practice, guidance, and repetition. The
dojo provides a structured environment for employees to receive
training tailored to their specific roles and responsibilities.
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C HAPTER 7: 12 TYPES OF DOJO
1. Know my company
One of the key aspects emphasized during this stage is instilling a sense
of pride in the employees toward their organization. By providing them
with a comprehensive understanding of the company's history, values,
mission, and achievements, employees are encouraged to develop a
deep appreciation for the organization they are a part of. This pride
serves as a motivational factor, driving employees to perform their best
and contribute to the overall success of the company. To know more
about the List of Equipment. (Click here)
2. Safety DOJO
The training program's "Safety Dojo" level underscores the critical
significance of safety across all production areas. It fosters a safety-
first culture and provides employees with the expertise, abilities, and
attitude needed to recognize and manage risks efficiently. Various
training sessions within the Safety Dojo target distinct safety issues to
guarantee thorough adherence to safety protocols. To know more
about the List of Equipment’s. (Click here)
3. Product DOJO
The training program's "Product Dojo" level aims to improve employees'
comprehension of the products they manufacture or handle. This level
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highlights the significance of product knowledge in
guaranteeing quality, efficiency, and customer satisfaction. By
acquainting workers with the products they create, organizations
enable them to take responsibility for their work and make informed
choices that drive overall success.(Click here)
4. 5 Senses DOJO
The training program's "5 Senses Dojo" level aims to enhance
employees' awareness of their environment and actions by utilizing
their five senses: touch, sight, hearing, smell, and taste. This level
highlights the significance of engaging all the senses to improve
productivity, safety, and overall job performance.(Click here)
6. Production DOJO
"Process and Machine Dojo" level within the training program is
specifically designed to equip workers with the essential knowledge and
skills required for the safe and effective operation of machinery and the
navigation of various processes on the shop floor. This comprehensive
training emphasizes the importance of routine operations as well as the
ability to handle hazardous situations, ultimately ensuring the well-
being of employees and the seamless functioning of production
processes.(Click here)
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7. Quality DOJO
The training program's "Quality Dojo" level aims to cultivate a culture of
excellence in quality among employees. Through this training, workers
are equipped with the necessary knowledge, skills, and mindset to
produce high-quality products while minimizing waste and maximizing
productivity.(Click here)
8. Maintenance DOJO
The "Maintenance Dojo" training module aims to provide workers with
the necessary knowledge and skills for Maintaining manufactured
products effectively. It includes preventive maintenance,
troubleshooting techniques, and routine inspections to uphold product
quality.(Click here)
9. Ergonomic DOJO
The "Ergonomic Dojo" level in a training program aims to improve
employees' understanding of body posture and ergonomics, leading to
increased productivity and a decrease in workplace injuries. This
training provides employees with the necessary knowledge and skills to
maintain correct posture, optimize body mechanics, and minimize
physical strain during work tasks.(Click here)
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classroom settings, these dojos immerse participants directly into the
heart of operations, providing a holistic education that blends theory
with practical application. On job training within a manufacturing dojo is
more than just a learning experience; it's a journey of discovery, growth,
and empowerment. Through hands-on immersion, guided mentorship,
and relentless pursuit of excellence, participants emerge not only as
skilled professionals but as torchbearers of innovation, poised to shape
the future of manufacturing.(Click here)
12. Certification
Upon completion of the rigorous training program within our esteemed
dojo, participants are awarded a Certificate of Achievement. This
certificate serves as a tangible recognition of their dedication, hard
work, and mastery of essential skills in their respective fields. It signifies
not only the culmination of their training journey but also their
readiness to apply their newfound knowledge and expertise in real-
world manufacturing settings. With this certificate, participants join a
prestigious community of skilled professionals, poised to make
meaningful contributions to the industry and drive innovation forward.
(Click here)
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CHAPTER 8: ADAPTING DOJO TRAINING
FOR INDUSTRY4 .0
As we move further into the era of Industry 4.0, characterized by the
integration of advanced digital technologies into manufacturing
processes, the future of lean manufacturing is evolving rapidly. In this
context, adapting DOJO training methodologies becomes essential for
fostering continuous improvement, empowering employees, and
driving innovation in the manufacturing sector. Here's a look at how
DOJO training can be tailored to meet the demands of Industry 4.
3. Cross-Functional Collaboration:
Enhance interdepartmental cooperation through the organization of
DOJO training sessions involving employees from various departments
and fields.
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4. Real-Time Data Analysis and Decision-Making:
Instruct staff on utilizing real-time data analytics and visualization tools
for monitoring and enhancing manufacturing performance effectively.
Educate individuals on utilizing data-driven insights to make informed
decisions and consistently enhance processes within the factory setting.
7. Environmental Sustainability:
Integrate environmental sustainability into DOJO training to educate
staff on resource conservation, waste reduction, and eco-friendly
practices. Encourage inventive strategies to reduce the environmental
footprint across the manufacturing value chain.
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C HAPTER 9: DOJO SKILL IN TOTA L
PRODUC TIVE MAINTENANCE E ( TPM )
1. Focused improvement
2. Autonomous Maintenance
3. Planned Maintenance
4. Education & Training
5. Early Equipment management
6. Quality Maintenance
7. Safety, health & environment
8. Office TPM
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CHAPTER 10: DOJO SKILLIN W ORLD CLASS
MANUFACTURING ( WCM)
One of the key aspects of DOJO within the WCM framework is employee
engagement. By providing a dedicated space for training and
development, DOJO encourages employees to actively participate in
learning activities, fostering a sense of ownership and commitment
towards their personal growth and the organization's success. This
engagement is crucial for creating a culture of continuous improvement
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and innovation within the company.
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engagement, communication, measurement, standardization, and
documentation, with a specific emphasis on People Development. By
providing a dedicated space for training and development, DOJO
enables organizations to create a culture of continuous improvement,
and foster effective.
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CHAPTER 11: PLANNING AND IMPLEMENTING
DOJO TRAINING
1. Set Clear Objectives:
Outline DOJO training objectives, such as improving coding proficiency,
fostering collaboration, enhancing critical thinking, or expediting
project completion.
2. Identify Participants:
Involve developers, testers, project managers, and other stakeholders
in DOJO training. Encourage diverse skill levels and backgrounds for
enhanced peer learning.
4. Allocate Resources:
Allocate essential resources like training materials, development
environments, and tools to effectively support DOJO training sessions.”
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remember to foster a culture of continuous improvement by
integrating DOJO principles into daily operations.
5. Schedule Sessions:
Plan DOJO training sessions strategically, considering participant
availability and avoiding critical project phases for maximum
engagement.” Remember to foster a culture of continuous improvement
by integrating DOJO principles into daily operations.
6. Monitor Progress:
Consistently monitor the progress of participants and the impact of the
training sessions. Obtain feedback from both participants and
facilitators to identify opportunities for improvement and implement
necessary changes.
7. Measure Results:
Examine the impact of DOJO training on participants' skills, productivity,
and overall team performance. Success can be measured through
metrics such as code quality improvements, time-to-market reductions,
and employee satisfaction levels.
8. Continuous Improvement:
Enhance the training program by incorporating feedback and insights
gained from past sessions. Regularly revise the syllabus, introduce fresh
subjects, and improve teaching methods to maintain its efficacy over
time.
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ABOUT TETRAHEDRON
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