DOJO Training Assessment Checksheet

Vendor Name & code : Vendor Location:

Total Operator
Permanent : Contractual : Date:
Strength :

S. No. Check Point Score Observations

Recrutment, Training Process, Trainer evaluation

1 Duration of training in DOJO Is the duration of Training in DOJO of new manpower adequate ?

2 Is recruitment being done in batches ?

3 Is there any defined new manpower selection criteria for associates

Recruitment policy

4 Is the attrition/absenteeism record of Manpower available and monitored?

Is there any bench strength maintained based on attrition rate ? (Is there
5
sufficient time to train the new recruit ?)

6 Does Vendor have training procedure for New & Existing associate ?

7 Does vendor plan Retraining in case of absenteeism in training ?

8 Is there a criteria of Multiskilling of Operators & plan made accordingly

Is there any TNI / competency matrix made for Existing associates &
9
Training Process & curriculum supervisor ?

10 Does vendor made training plan of supervisors as per TNI?

Does Vendor have a well defined Curriculum for training of new manpower in
11
DOJO ?

Does Vendor have a defined curriculum for specific need based training of
12
existing manpower ?

13 Does vendor have a defined curriculum for supervisors ?

Is there any Policy or rule available - "No new manpower will go on Shop
14 Training Rule/ Policy
Floor without completion of DOJO Training"?

Is DOJO sequence as per below details

Company Overview--> Safety DOJO--> Product DOJO-->5 Senses DOJO-->
15 Dojo Sequence
Production Rule DOJO-->Inspection DOJO-->Process DOJO--> Maintenance
DOJO

Is DOJO Center incharge defined and available for managing the Training
16
operations

DOJO In-charge Is DOJO Center incharge fulfill trainer selection criteria like:
17 - Desirable 5 Yrs. min. hands on experience in company
- Good communicator & knows Regional & English Language )

Are qualified Trainers available and being used for giving training on various
18 Qualified Technical Trainer
modules in the DOJO center

DOJO Facility evaluation :

19 Classroom Facility Is proper Class room available for Theoretical training ?

Displays / Boards / Equipment etc. for training on all Basic Safety aspects
20 relevant to the Organization ?
Safety DOJO - (eg. Fire extinguisher, emergency escape route, Assembly place etc.)
Have Simulators been provided to sensitize about 'Safety aspects?
21
- (e.g. : Safety shoes/Hot object/Air Pipes/ Conveyorised Belt etc.)
Are Simulators provided to develop the '5 Senses' of Trainees ?
22
- (e.g. Walking practice/Hand eye co-ordination/Bolt pick-up etc.)
5 Sense & Behavioral DOJO
Is usefulness of above 'Senses' simulators on actual shop floor understood &
23
explained ?
Displays / Models etc. provided to explain various products of the company
24
(including their Child parts) ?
Product DOJO
Is Fitment & Function of their products in customer vehicles explained with
25
car models/ some other methods etc. ?

26 Is Vendor explaining Do's & Don'ts at shop floor?

27 Is Vendor explaining 4M Change Control ?

28 Is vendor explaining NG Part/ Rework parts control ?

29 Is vendor explaining about Set-up approval System?

Production Rules DOJO
(Critical)
Is vendor explaining about Abnormality handling (STOP, CALL , WAIT Concept)
30
?

31 Is vendor explaining FIFO & Material Handling rules ?

32 Is Vendor explaining Machine & Poke Yoke checksheet?

(C) 2019 Maruti Suzuki India Limited

 33 Does vendor have a list of manual CTQ processes?

Does vendor have a list of manual CTQ processes & all CTQ Processes as per
34
manual CTQ processes list covered in Process DOJO ?

35 Does the Trainee get sufficient hands on training on all Process stations?
Process DOJO (Critical)

Do the Process DOJO stations have adequate quantity of Input parts /

36
simulated parts to be able to provide Practical Training to Trainees.

Are Qualifying requirement available for passing the Process DOJO by the
37
Trainee (eg.- WI adherence , Cycle Time achievement etc.)

Does the vendor have a Defect Gallery with actual defective parts or on
38
Parts?

Does the vendor have the following facility for Training:

- Measuring instruments & parts for practice
39 Quality DOJO - Gauges / Fixtures for fitment check
(Critical) - Inspection standards
- Replica of Final Inspection station

Is Defect Identification/catching test conducted on Trainees to judge their

40
capability to catch defects?

41 Is vendor explaining Maintenance procedure & checksheet?

Maintenance DOJO
42 Is vendor explaining basic maintenance tools?

DOJO center evaluation & effectiveness :

43 Does vendor have a proper evaluation method of operators after training?

44 Does vendor do practical evaluation post OJT.

Is there any certification criteria for associates deployed for special & critical
45
process?

Does vendor periodically monitor the skill of certificated operators and

46
follow up to improve their skill?
Evaluation

Prior to SOP, do you instruct each operator based on actual operation

47
instructions? (In New Model)

Adherence of Training plan made for taking operator to the next skill level or
48
multiskilling.

49 Adherence of Training plan of supervisor

50 Is DOJO center being properly utilized for training of new manpower?

How many days DOJO is being used for New Manpower & Existing Manpower
51
training.
DOJO Utilization

Are there any specific guidelines & calendar available for DOJO training of
52
existing manpower?

Is manpower at actual station deployed as per the skill level, especially for
53
Critical/ Maru A processes? If not, is 4M Change record available?

Are the records of Internal Rejections caused by DOJO trained Manpower

54
available?

Effectiveness check on DOJO Are the records of Customer defects caused by DOJO trained Manpower
55 Trained Manpower available?

56 Is the Dojo Scorecard available and monitored?

Does vendor take action in terms of Dojo curriculum or facility improvement

57
for any manpower related defect reported from customer ?

Is there any improvement action plan for weak areas identified in

58
effectiveness (Question :53-57)

59 Is Dojo Training Effectiveness scorecard reviewed by management?

Top Management Review

60 Does management do periodic audit of Dojo for its utilization

Total Score
Legend : 0 - No System Available; 1 - System Available Partially; 2- System completely available & adhered

MSIL Assessor Sign Plant Head/CEO Sign

(C) 2019 Maruti Suzuki India Limited
 Is the duration of Training in Training given to trainees for 4-6 Days 2
1 DOJO of new manpower Training given to trainees for 3 Days 1
adequate ? Training given to trainees for less than 3 Days 0
Is recruitment being done in Recruitment done in batches at fixed interval like weekely, forthnigthly or
2
batches ? monthly
2
(to facilitate proper training Recruitment done in batches but not adhered completely 1
in DOJO) Recruitment done on daily or randomly without planning 0
Is there any defined new Initial written test screening & interview 2
3 manpower selection criteria Only interview 1
for associates Direct recruitment (Without test & interview) 0
Is the attrition/absenteeism Attrition & absenteeism record available for manpower 2
4 record of Manpower Attrition & absenteeism record partially available for manpower 1
available and monitored? Attrition & absenteeism record not available for manpower 0
Is there any bench strength Benchstrength maintained as per attrition data (100% ) 2
5 maintained based on attrition Benchstrength partially maintained as per attrition data (upto 50%) 1
rate ? (Is there sufficient time Benchstrength not maintained as per attrition data (0 or >50%) 0
Training procedure available, adequate for new & existing associate 2
Does Vendor have training
6 procedure for New & Existing Training procedure available not adequate for new & existing associate 1
associate ?
Training procedure not available 0
Retraining done in 100% absenteeism cases 2
Does vendor plan Retraining
Retraining done upto 60% absenteeism cases 1
7 in case of absenteeism in
Retraining done > 60% absenteeism cases 0
training ?
Retraining not done in case of absenteeism 0
Multiskilling criteria and as per that plan available 2
Is there a criteria of
Multiskilling criteria available but plan not available 1
8 Multiskilling of Operators &
Multiskilling plan available but criteria not available 1
plan made accordingly
Multiskilling criteria & plan not available 0
TNI/Competency matrix made for all associates & supervisors 2
Is there any TNI / competency TNI/Competency matrix made but not covered all associates & supervisors 1
9 matrix made for Existing
TNI/Competency matrix made for all associates but not supervisors 1
associates & supervisor ?
TNI/Competency matrix made for all supervisors but not associates 1
TNI/Competency matrix not made associates / supervisors 0
Training plan of all supervisor available as per TNI 2
Does vendor plan training of
10 Training plan made but all supervisor not covered 1
supervisors as per TNI?
Training Plan of supervisor not available 0
Does Vendor have a well Daywise curriculum available covering Training Topics, Duration, Trainer,
2
defined Curriculum for Location etc.
11 training of new manpower in Daywise curriculum available but details like Training Topics, Duration,
1
DOJO ? Trainer, Location not defined
- (Training Topics, Duration, No written curriculum available 0
Special need based trainings for CTQ, Special process identified & schedule
2
Does Vendor also have available
defined curriculum for Special need based trainings for CTQ, Special process identified but not
12 1
specific need based training scheduled
of existing manpower ?
Special need based trainings not identified & schedule or plan not available 0
Curriculum available for supervisors covering Training Topics, Duration,
2
Trainer, Location etc.
Does vendor have a defined
13 Curriculum not available for supervisors but details like Training Topics,
curriculum for supervisors ? 1
Duration, Trainer, Location not defined
No written curriculum available 0
- Is there any Policy or rule Rule or Policy available 2
14
available " No new Rule or Policy not available 0
Is DOJO sequence as per Dojo Training center developed as per defined sequence 2
below details Dojo Training center not developed as per defined sequence but training
15 1
Company Overview--> Safety sequence is followed
DOJO--> Product DOJO-->5 Dojo Training center not developed as per defined sequence 0
Is DOJO Center incharge Dojo Trainer available for full time basis 2
16 defined and available for Dojo Trainer available for part time basis 1
managing Training operations Dojo Trainer not available 0
Is DOJO Center incharge fulfill Dojo Trainer completely fulfill selection criteria 2
17 trainer selection criteria like: Dojo Trainer partially fulfill selection criteria 1
- Desirable 5 Yrs. min. hands Dojo Trainer not fulfill selection criteria 0
Are Qualified Trainers
Modulewise trainer identified & he is supervisor of process or his skill level L4
available and being used for 2
18
giving training on various Modulewise trainer identified but his skill level less than L4 1
modules in the DOJO center Modulewise trainer not defined 0
Is proper Class room Separate classroom for theoretical training with all amenities available
2
available for Theoretical
19 Classroom clubbed with Dojo center or canteen , conference room used on
training ?
conditional basis 1
Classroom for theoretical training not available 0
PPE's & its process wise application, Fire extinguisher, Emergency evacuation
Displays / Boards / plan physically available & practiced (All 03 available) 2
Equipment etc. for training
PPE's & its process wise application, Fire extinguisher, Emergency evacuation
on all Basic Safety aspects
plan physically available & practiced (Only 02 items available)
relevant to the Organization 1
20 ? PPE's, Fire Extinguisher & Emergency evacuation explain theoretically
- (eg. Fire extinguisher, through display or presentation 1
emergency escape route,
PPE's & its process wise application, Fire extinguisher, Emergency evacuation
Assembly
plan physically available & practiced (Only 01 items available)
knowledge etc.) 0
None of them available 0
Have Simulators been 02 Simulators available 2
21 provided to sensitize about 01 simulator available 1
'Safety aspects'? No simulator 0
Are Simulators provided to 2-3 simulators available 2
22 develop the '5 Senses' of 1 simulator available 1
Trainees ? No simulators available 0
Is usefulness of above Guideline of simulator with actual process is made & explained 2
'Senses' simulators on actual Guideline of partial simulator with actual process is made & explained
23
shop floor understood & (Atleast 50%) 1
explained ? Guideline of simulator with actual process not made & explained 0
All Product types along with child part/ raw material displayed & explained
2
Displays / Models etc.
All Product types explained but child part/ raw material not displayed
provided to explain various
24 &explained 1
products of the company
All product types not displayed & explained 1
(including their Child parts) ?
No physical product available & only Photographs displayed & explained
0
Is Fitment & Function of Product fit & function explained through Car model, Cut Section 2
25 their products in customer Product fit & function explained through AV or presentation 1
vehicles explained with car Product fit & function not explained by any method 0
Vendor explaining Do's & Don’ts at shop floor through display 2
Is Vendor explaining Do's &
26 Vendor explaining Do's & Don’ts at shop floor through presentation 1
Don'ts at shop floor?
Vendor not explaining Do's & Don’ts at shop floor by any method 0
Vendor explaining 4M change guidelines, formats & actual practiced 2
Is Vendor explaining 4M Vendor explaining 4M change guidelines & formats but not practiced 1
27
Change Control ? Only 4M change guidelines explained but format not explained 1
Nothing explained related to 4M change 0
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 Vendor explaining NG Part / Rework part control guidelines and also
practiced actual checksheets 2
Vendor explaining NG Part / Rework part control guidelines but practice on
Is vendor explaining NG
28 actual checksheets not done 1
Part/ Rework parts control ?
Vendor explaining NG Part / Rework part control guidelines but checksheet
not explained 1
Nothing explained related to NG / Rework part control 0
Vendor explaining Set-up approval guidelines and also practiced actual
checksheets 2
Is vendor explaining about Vendor explaining Set-up approval but practice on actual checksheets not
29
Set-up approval System? done 1
Vendor explaining Set-up approval but checksheet not explained 1
Nothing explained related to Set-up approval 0
Vendor explaining Abnormality handling rules (STOP, CALL , WAIT Concept) &
reaction plan for quality confirmation practiced 2
Is vendor explaining about
30 Abnormality handling (STOP, Vendor explaining Abnormality handling rules (STOP, CALL , WAIT Concept)
CALL , WAIT Concept) ? but reaction plan for quality confirmation not explained or practiced
1
Abnormality handling (STOP, CALL , WAIT Concept) not available 0
FIFO & Material Handling rules explained & infrastructure like different colour
bins , Trolleys , In-Out board available 2
Is vendor explaining FIFO &
31
Material Handling rules ? FIFO & Material Handling rules explained but infrastructure not available
1
FIFO & Material Handling rules not explained 0
Is Vendor explaining Checksheet explained & practiced 2
32 Machine & Poke Yoke Checksheet explained but not practiced 1
checksheet ? Checksheet not explained 0
Complete List of Manual CTQ processess available 2
Does vendor have a list of
33 Partial or Incomplete List of Manual CTQ processess available 1
manual CTQ processes?
CTQ processes list not available 0
All CTQ stations mapped, installed in Dojo 2
Does vendor have a list of
All CTQ stations mapped but partially installed in Dojo 1
manual CTQ processes & all
34 CTQ Processes as per manual All CTQ stations mapped & explained through proto machine or fixture
1
CTQ processes list covered in
All CTQ stations mapped & explained through video or AV 1
Process DOJO ?
CTQ stations not mapped & not explained by any method 0
Does the Trainee get Hands on training given in Process Dojo at 100% stations 2
35 sufficient hands on training Hands on training given in Process Dojo atleast 50% stations 1
on all Process stations ? Hands on training not given in Process Dojo 0
- Do Process DOJO stations Parts available for hands on practice for 100% stations 2
36 have adequate Quantity of Parts available for hands on practice for atleast 50% stations 1
Input parts / simulated parts Parts not available for hands on practice 0
- Do they have Qualifying Qualifying criteria like WI followed , Cycle Time achievement for passing
requirement for Passing process dojo is available, adhered & monitored 2
37 Process DOJO by the Trainee Qualifying criteria like WI followed , Cycle Time achievement for passing
(eg.- Parts produced, NG process dojo is available but partially adhered & monitored 1
parts , TAKT Time Qualifying criteria for passing process dojo not available 0
- Sensitization of Quality Defect Gallery with OK & NG parts available 2
Defects Defect Gallery with only NG parts available 1
38
Do vendor has set following Defect Gallery display through photographs & presentation 1
facility for Training - Defect Gallery not available 0
- Training on Inspection Measuring Instruments, Gauges, Inspection standard , Checksheet & Final
Facilities . Does the vendor Inspection station available with actual practice done 2
have the following facility for Measuring Instruments, Gauges, Inspection standard, Checksheets & Final
39 Training - Inspection station available but actual practice not done 1
Measuring Instruments, Gauges, Inspection standard & checksheets available
- measurement equipment's but Final Inspection station not available. 1
& parts for practice Instrument , Gauges not available only photographs displayed 0
- Is Defect Identification/ Poison Cake test work instruction available & practiced 2
catching Test taken from Poison Cake test work instruction available but practiced partially 1
40
Trainees to judge their Poison Cake test work instruction available but not practiced 0
capability to Defects Poison Cake test work instruction not available 0
Is vendor explaining Maintenance procedure & checksheet not explained 0
41 Maintenance procedure & Maintenance procedure & checksheet explained 2
checksheet? Maintenance procedure explained but checksheet not explained 1
Maintenance tools explained through working models or actual tools 2
Is vendor explaining basic
42 Maintenance tools explained through display 1
maintenance tools?
Maintenance tools not explained 0
- Does vendor have a proper Evaluation done through Written test 2
43 evaluation method of Evaluation done Verbally 1
operators after training. Evaluation not done 0
Practical evaluation done covering Work Procedure adherence, Quality
- Does vendor do practical Check Points , Cycle time check Points , Safety & Discipline check points
44 2
evaluation post OJT.
Practical evaluation done but partially checkpoints covered 1
Practical evaluation not done or only recommendation by supervisor 0
Is there any certification Certification Criteria available & adherence as per that. 2
criteria for special & Certification Criteria available & adherence partially 1
45
authorized associates Certification Criteria available but adherence not done 0
(CTQ Station/ Special Certification Criteria not available 0
Does vendor periodically Operator observance plan & adherence is done for all. 2
46 monitor the skill of Operator observance plan available with partial adherence 1
certificated operators and No operator observance plan 0
New Model specific training given to all operators before SOP 2
Prior to SOP, do you instruct
47 each operator based on New Model specific training given but all required operators not covered.
1
actual operation instructions?
New Model specific training not given . 0
Adherence of Training plan Training plan adherence for multiskilling is 100% 2
48 made for taking operator to Training plan adherence for multiskilling is 70% - 99% 1
the next skill level or Less than 70% adherence to training plan 0
Training plan adherence for supervisors is 100% 2
Adherence of Training plan of
49 Training plan adherence for supervisors is 70% - 99% 1
supervisor
Less than 70% adherence to training plan 0
- Is DOJO center being If 100% new manpower trained in Dojo 2
50 properly utilized for training if 70% - 99% new manpower trained in Dojo 1
of new manpower . Verify at Less than 70% new manpower trained in Dojo 0
- How many days DOJO is
Dojo utilization days available for both New & Existing manpower as per plan
being used for New 2
51
Manpower & Existing Dojo utilization days available for only New or Existing manpower 1
Manpower training. No recording of Utilization 0
- Is there any specific Existing Manpower training calender, guidelines available & adhered 2
guidelines & calender Existing Manpower training calender, guidelines available but partially
52
available for DOJO training adhered 1
of existing manpower, When Existing Manpower training calender, guidelines not available 0
100% manpower deployment as per skill level defined. 2
70% - 99% manpower deployment as per skill level & 4M change record
- Skill Level Vs Process
available 2
Implementation as per
70% - 99% manpower deployment as per skill level & 4M change record
53 requirement (Critical/ Maru
partially available 1
A) - to be checked on shop
70% - 99% manpower deployment as per skill level but 4M change record
floor
not available 0
Less than 70% manpower deployment as per skill level 0
- Check records of Internal Internal rejection recording for Dojo trained manpower done 2
54 Rejection by DOJO Trained Internal rejection recording for Dojo trained manpower partially done 1
Manpower Internal rejection recording for Dojo trained manpower not done 0
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 - Verify records of Customer
55 Defects reported by DOJO
Trained Manpower
Does the Vendor Monitor the
56 Dojo Training Effectiveness
Scorecard
Does vendor take action in
terms of Dojo curriculum or
57 facility improvement for any
manpower related defect
reported from customer ?
- Is there any improvement
58 action plan for weak areas
identified in effectiveness
- Is Dojo Training
59 Effectiveness scorecard
reviewed by management?
- Does management do
60 periodic audit of Dojo for its
utilization
Customer defect recording w.r.t Dojo trained manpower done 2
Customer defect recording w.r.t Dojo trained manpower partially done 1
Customer defect recording w.r.t Dojo trained manpower not done 0
Scorecard is available, updated and displayed 2
Scorecard available but not updated or displayed 1
Vendor does not maintain the scorecard 0
Action taken in Dojo center for all Customer reported manpower defects
2
Action taken in Dojo center but all Customer reported manpower defects not
covered 1
No action taken for Customer reported manpower defects 0
Periodic review for weak area identification & corrective action taken 2
Periodic review done for weak area identification & corrective action
partially taken 1
Periodic review & Action plan not available for improvement . 0
Dojo Training Effectiveness score card not being reviewed by management/
Plant Head or HR head 0
Dojo Training Effectiveness score card reviewed by Plant Head 1
Dojo Training Effectiveness score card reviewed by HR Head 1
Dojo Training Effectiveness score card is review by management 2
Quaterly Audit done by management 2
Half Yearly / Yearly Audit done by management 1
No audit done by management 0
(C) 2019 Maruti Suzuki India Limited