DENSO

DOJO Establishment Proposal Sharing in DNHA-J

<Agenda>
 Background
 Proposed DOJO concept
 Objective & Thinking Way
 Various DOJO Corners
 Evaluation method & criteria
 Training Flow & Timeframe
 Proposed Layout
 Budget Requirement
 Implementation Schedule

Venue: MPR
Date: 05/07/2018
Time: 12:00~12:45
DENSO DOJO Establishment in DNHA P-2
<Background>
Training Methodology: Existing Condition
(Classroom + Practical)
New TM Join DNHA Training program provided to newly join TMs Handover to PRD

@ Line

HRD Orientation
(3 days Duration)
Plant-1/2
HRD coordinate the
Training programme
Academy Training
(3 days Duration)
Plant-1
PID coordinate the
Training programme
 Basic off JT on 5S & After Evaluation TM sent to
PRD rule(Drop Part) specific “PRD LINE” for On
(1 Day Duration) Job Development
Depute to specific line
for OJT

6 day duration before handing over to PRD

<HRD Orientation Content> → 3 day program
1. PPE’s distribution , TM no allocation
Joining
2. Company profile sharing
formalities
3. Denso philosophies & principles
1. Code of compliance
Basic 2. Kaizen , QA and TS understanding
3. Awareness of Denso atarimae
Awareness
4. HR & Time office policies
5. Employee welfare activities
<Academy Training Content> → 3 day program
General Awareness → (Production rules + Behaviour)
Classroom
1. PPEs , 5S , Leave management system etc
Training 2. FIFO , KPI , QCDSM , MSDS , Safety overview , Safety
atarimae , One cycle stop , stop call wait etc
Practice → Safety DOJO , Operation speed & accuracy
Practical 1. Safety sensitivity , JI , OMS reading , 3S demo etc
Training 2. Operation speed (card , peg board , tobacco kit)
3. Basic TIE , Safety glass simulation , Screw tightening

Product Product Awareness → Fitment , Kakotora items

1. PRD-ECU , ETB/VCT , FP , INJ , Meter
Education , O2 , CRS
Only Plant-1 product education provided to new
1 joinees → Plant-2 product not covered in this session
1. Past customer claim & their root cause
Quality
2. Explanation of product fitment in car & impact of NG
Hiroba product on car
3. Explanation of product assembly through video
2 Only P-1 related product fitment , Kakotora items , Quality
problems explained to TMS → Plant -2 product not covered
DENSO DOJO Establishment in DNHA P-2
<Loop holes in Existing System> <Objective>
 To develop a common basic P-2 related product & process
No Plant-2 product P-2 product & process not awareness in all team members (New joinees+ Existing TMs)
education clear to TMs  Coverage of all Temporary team members through minimum
No awareness on P-2 common basis DENSO Mfg. system & training related to product.
kakotora items  To develop Safety & Quality sensitivity among all TMs to avoid
This may lead to –
• Quality concerns(Customer claim) any Safety concerns and Customer claims.
Process DOJO not
available • High inline rejection(More defect) Major Focus Area
• Safety concerns(Less awareness)
No Inspection & • Less productivity (OR loss)
• Low morale of new TMs P-2 Product Safety & New +
Maintenance DOJO & Process Quality Existing TMs
<Proposed Training Concept>
DOJO will be established in DNHA-J Handover to PRD
New TM Join DNHA specially for Plant-2 TMs
@ Line

<Duration : 3 day → 1.5 day> <Duration : 3 day → 1.5 day> <Duration : 3 day >  Basic off JT on 5S &
HRD Orientation Academy Training Centralized DOJO PRD rule(Drop Part)
(1.5 days Duration) (1.5 days Duration) (3 days Duration) (2 Day Duration)
Plant-1 Plant-1 Plant-2
HRD coordinate the PID coordinate the System Group will coordinate Depute to specific line
Training programme Training programme the Training programme for OJT

6 day duration(3 day P-1 & 3 day P-2) before handing over to PRD

 In addition to 3 day training at P-1 , 3 day additional training program will be

provided to TMs who will join DNHA-J plant . Centralized Training
Centre in P-2 →
 Major focus area will related to P-2 product , process , kakotora items and other (Classroom + Practical)
safety & quality aspects.
DENSO DOJO Establishment in DNHA P-2
<DOJO Training Objective → Zero Defect Initiative>

 New Manpower : Off the Job training & practice session to new manpower before deputing to shop floor
 Regular Manpower : To improve Sensitivity & Quality skills

 As a part of making qualitative and highly reliable products, We are assessing our team members communication,
information sharing & Understanding on three main angles -
New TM  Mind development
Centralized DOJO
(3 days Duration)  Knowledge enhancement
Existing TM
(Perm. + Cont.)  Skill improvement
<Thinking Way> → Systematic Approach - 8 Steps <P-2 DOJO Requirement>
1 Company Overview P-2 DOJO
Covered under HR
2 Safety DOJO orientation and Academy Product Process Quality & Insp. &
Training at P-1 Knowledge Awareness Safety Maint.
3 Behavioural & 5 Sense DOJO (Classroom + Practical)
DOJO
Main 4 Production Rules  P-2 product knowledge & awareness
Pillars Covered only for P-1  Process know how & practice session
5 Product Knowledge
product → P-2 product  Quality related training session and
6 Quality DOJO not covered awareness about customer claims
 Awareness related to safety concerns
7 Process DOJO  Inspection & Maintenance training
Process , Inspection &
8 Inspection & Maintenance DOJO Maintenance DOJO not
available (Classroom + Practical) Training programs
DENSO DOJO Establishment in DNHA P-2
<Proposed Various DOJO Corners>
Technical Training (Practical) Classroom Training

P-2 Product Safety

DOJO
DOJO DOJO

Maintenance
Quality DOJO
Process DOJO DOJO

<Classroom Training>
Classroom training program will include –
 Process Knowledge
 P-2 Product Education  P-2 Kakotora Item Explanation i. P-2 process awareness
i. Knowledge of Denso products i. Past customer claim awareness ii. Process sequence explanation
ii. Customer & Vehicle names ii. Root cause of customer claim iii.Explanation of product assembly
iii.Function of different products iii.Impact on end user in case of failure through video

Common process explanation

DENSO DOJO Establishment in DNHA P-2
Technical Training <Product Knowledge>
Product knowledge will include basic knowledge about DNHA-J product , their function , integral parts etc. Each product
fitment in car will be elaborated in detail and their importance will be explained.
<DNHA-J Products> <Function Explanation> Radiator
Fin
For all the products → fitment , 1. ECM Cap Tube
Function +
Fitment + function & their integral part
Integral Part related explanation will be covered

Different products of DNHA-J Plant

Tank
Motor Division Thermal Division Core Plate
ECM (Radiator + Engine Cooling Fan) Insert
FAN Motor Blower Motor ECM
What is a Radiator & its Function?
 The radiator is a type of heat exchanger,
which is an integral part of the cooling
system.
Wiper Motor PW Motor HVAC  It is designed to transfer heat from the
hot coolant that flows through Radiator
to the air.
2. Blower Motor
<Fitment Explanation> What is a Blower motor & its Function?
 Blower motor is a permanent magnet
type DC electric motor.
 It is used in Ventilator Assy. for blowing
air inside the vehicle.
Integral Parts:
1. Housing Assy.
2. Armature
3. Bracket
4. Lead wire with connector
DENSO DOJO Establishment in DNHA P-2
<Quality DOJO> It will include the practical awareness about P-2 past customer claims , their root cause and outflow
reasons. Also awareness will be provided about impact on end user in case product failed due to human mistake
Concept Past Customer Claim Awareness
 Based upon these pillars  Gallery will be prepared
Past Customer where all P-2 past
Quality DOJO will be
Claim customer claim will be
established -
Quality DOJO

 To provide awareness explained to TMs

Impact on end user about Kakotora items  Root cause and outflow
 Realisation about impact reason will be
on end user in case of demonstrated to TMs
Defect Gallery product fail.  Countermeasure taken
 Sensitivity up and Quality against the claim will be
Mind set through practice explained and their
Similar looking of part and defect impact on vehicle will be
parts segregation explained

Impact on end user due to product fail Defect Gallery & Similar looking parts

Criticality level Similar part segregation Defect segregation gallery for sensitivity up
Problem

Accuracy of part identification

Similar part segregation
Impact on end user
OK/NG condition
TM sensitivity level up

Defect segregation
Role of Team Member Quality Mind Set Develop
DENSO DOJO Establishment in DNHA P-2
<Process DOJO> It will include the practical training of P-2 basic and common process so that TM can understand
process know how , part handling , hand motion etc. so that TM accuracy can be improved & quality can be maintained
Process Selection Criteria Process Mapping
a) Common process identification Start
Incoming Process
PCD
Inspection A
Processes will be identified which is common in more than one line
C
and mostly basic process will be covered.
b) Critical process identification
Process Process Process
Critical processes will be identified based on product functionality ,
process design etc.
C D C B

C) Past defect history Final

PDI End
Inspection
Past defect will be identified and their root cause and outflow Based on study common & critical processes will be identified and
process will be replicated in DOJO same will be replicated in “DOJO Training Centre”
Critical & Common processes in PRD-2 Process selection Step wise training method → Eg. Gear Assy
for training will be
<Gear Assy> <Armature Assy>
based on
following factors

Process
Criticality
<Brush Tightening> <Name Plate Assy>

Basic PRD 2
process

Similar
processes
Same process will be replicated in “DOJO
Training Centre” for offline practice
DENSO DOJO Establishment in DNHA P-2
<Safety Dojo>
In the safety corner training will include basic line safety awareness , risk forecasting and emergency handling. So this
will Improve TM’s sensitivity towards safety concerns and enhance their safety predictive mind.
<Concept> <Training Approach>
Carelessness Aging
Need to inherit safe
Theoretical
Human
behaviour in TM’s & Risk forecasting
Equipment
Misconception Wear
Enhance sensitivity
Neglect Deformation
Safety Sensitivity General Awareness
Human mistakes Equipment failures Training

× Accident Emergency Handling

Unsafe behavior Unsafe condition Hazards
Practical
Event

<Basic Production Safety Awareness> 3. Safety demo on Simulators 4. Fire prevention and training of
1. General Awareness 2. Type of accidents fire extinguisher operation
1) Falling down
2) Burn
3) Cut
4) Hand Jam Risk of Hidden Hand caught in
How to avoid the accident? portion chain

Static sim Elect. Shock

Hit the heal
>> Develop the sense of risk
>> Traffic rule forecasting.
>> Abnormality handling >> How to handle the situation
>> Standard safety norms >> How to reset the abnormality Operation of Fire Extinguisher
DENSO DOJO Establishment in DNHA P-2
<Evaluation step , Method & Evaluation Criteria >
S.no Evaluation step Method Evaluation Criteria
1 Product Awareness Confirm awareness about all DNHA-J product 1 For each evaluation steps contain 10 points
2 Quality mind set Confirm awareness about past claim & practical judgment 2 For each mistake can loose 2 points
3 Process know how(practical) Following the work procedure without skipping any step 3 Exceeding the std time (> 5sec) can loose 1 point
4 Safety awareness By checking their sensitivity at safety simulators 4 Not following the procedure can loose 1 point
5 Practical performance By achieve the target time as per TIE standard 5 In case of sequence miss can loose 2 points

<DOJO Graduation Method> <Training Material & Trainer Development>

 The DOJO batch will be handover
to passed trainee along with OJT
batch.
 The trainee should wear the
batch on the cap (Batch should
be wear for 2 weeks)
DOJO graduation
batch
Training Material
Training material will be prepared based upon below categories –
1. Classroom training material
Theoretical 2. Training kits for product awareness ,
process DOJO , Quality & Safety
+ 3. Actual product with their integral parts
Practical 4. Training procedures
5. Evaluation test papers

Training material will be prepared considering that it should be

 If trainee evaluation score is less easy to understand by newly joined TMs and procedures will be
than the target , then retraining prepared in a identical manner as available on shop floor.
will be provided to the trainee &
again evaluation will be done
Trainer Development

 The skill matrix of trainee will be No of trainers Identify Trainer

issued while handed over to the required potential trainer development
respective line 1. Classroom Training → HRD & PRD TL will provide training
2. Product Knowledge → TL from various sections
Multi skill chart
To get certified , the trainee 3. Process DOJO→ PRD TM will developed as trainer
must score minimum 80% 4. Maint. & Insp. → PRD TM will developed as trainer
points in evaluation test paper 5. Quality →QAD & PRD TL will be developed as trainer
6. Safety →EHS will provide safety related training
DENSO
<Training Flow & Timeframe>
New TM Join DNHA
HRD Orientation +
Academy Training
(3 day duration)
HRD orientation and Academy
training includes PRD basic rules
, manufacturing systems & some
practical training
Handover to PRD
@ Line
 Basic off JT on 5S &
PRD rule(Drop Part)
(2 Day Duration)
Depute to specific line
for OJT
DOJO Establishment in DNHA P-2
DNHA-J Existing TM (For temporary TMs / in case of internal
transfer / as per requirement)
Centralized DOJO (3 days Duration)
P-2 Product
Quality DOJO Process DOJO
DOJO
(0.5 day duration) (1 day duration) (1 day duration)
1. Classroom training – 1. Classroom training – 1. Classroom training –
1hr 1hr 1hr
2. Practical example of 2. Awareness about past 2. Awareness about
motor products – 1hr customer claim – 2hr common & critical
3. Practical example of 3. Impact on end user in processes – 1hr
thermal product– 1hr case product fail – 2hr 3. Offline practice on
4. Car fitment 4. Defect gallery & replicated processes –
explanation – 1hr similar part – 2hr 5hr
Maintenance &
Safety DOJO
Inspection DOJO
FY’19 Plan (0.5 day duration)
1. Classroom training –
 This will include –
 Defect awareness
1hr Total 6 days training
2. Practical training on
 Inspection standard program ( 3day → P-1
safety simulators – 1hr
awareness & 3 day → P-2) will be
3. Practical training of
 Equipment usage
 Tools awareness
fire prevention & conducted for P-2 TMs
extinguisher – 1hr
 Procedure
4. General awareness
explanation
about accidents – 1hr
DENSO DOJO Establishment in DNHA P-2
Proposed Location
& Layout Female Locker Room
Male Locker Room

Corridor

Canteen
Entry Future Room
DENSO DOJO Establishment in DNHA P-2
<Essential items & it’s budget requirement in Dojo>
As in current situation there is neither infrastructure nor dojo essential items are available to provide training to team
members in DOJO so to established Dojo there will be a requirement of certain budget to accomplish the task.

Room infrastructure related DOJO establishment related <DOJO establishment Costing>

 Electricity connection  Partition for classroom Main Area Item Required Approx. Cost
 Pneumatic connection  Table & chairs Floor tap & Stickers 2000
 Wooden Flooring  PC & Projector Layout Marking
Barricading's 10000
 False ceiling  Writing Board Aluminium Pipes 100000
 LED lights Installation  Benches for DOJO joints/Clamp/Bolt 15000
TIE Activity
 Air-conditioning  Electrical screw driver Ply/Carpet 20000
 Glass curtains  Measuring instruments PP Sheet, Acrylic Sheet 50000
 Smoke detectors  Mats, Acrylic & PP sheet Electrical Wiring/Ext. 10000
Electrical Item
 Emergency lighting  Practical instruments Installation
Screw drivers 150000
 PA system  Various stationaries PC & Projector 250000
Table & chair 30000
<Arrangement, Installation flow & responsibility> Equipment for
Writing board 5000
Product, Process &
Overall Lead Jig & Fixtures for products 50000
Inspection/Mtd.
(System Group) DOJO Dummy of poke yoke 3000
Limit/Boundary samples 2000
Room Infra. DOJO Infra. Kakotora visualizations 10000
Electric /Pneumatic o Table chair-GAD Tentative
Instrument for
Budget
Quality requirement
Demonstration kit 1.8 Million
50000
(Utility-MTD) o PC & Projector-ISD Quality, Safety Measuring instruments 100000
o Writing board, dojo DOJO All stations name plate 5000
bench, screw drivers,
Flooring, ceiling Glass Safety basis items 10000
measuring instruments
Curtain-GAD TIE related items 10000
& practical inst-PRD Visualization &
Stationaries 12000
Formats
o Mats, Acrylic-PP sheets Colour printing 4000
Detectors, PA system & & other TIE items- Basic Infrastructure 500000
Emergency lighting-EHS Room Infra
TIE/PRD Lights, AC & Curtains 350000
Developments
Smoke detector & PA system 70000
DENSO DOJO Establishment in DNHA P-2
DOJO Implementation → Micro Activity Plan
S.no Activity July Aug Sept Oct Nov Dec Jan Feb Mar FY’19

1 DOJO proposal preparation and approval

On-going
2 Layout finalization & approval

3 Preparation for Infrastructure development

4 Facility procurement/Installation in DOJO room

5 Establishment of classroom training program

6 Establishment of Product DOJO

7 Establishment of Process DOJO

Establishment of Quality DOJO (Visualization of

8
kakotora items and their training kit)

9 Establishment of Safety DOJO (Safety simulators)

10 Establishment of Inspection & Maintenance DOJO

Training curriculum & module preparation (Classroom

11
& Practical)

12 DOJO trainer identification & development

13 Final review by Management & Improvement

14 Start of training DOJO will be functional from Jan’19

Thank You
 Proposed Layout Dojo Establishment in DNHA P-2
800cm
Product DOJO
Blower Motor Fan Motor Wiper
ENTRY

Classroom Training

PW HVAC ECM

Quality DOJO Process DOJO

3160cm

Screw Tightening Bolt Tightening Similar part segregation Defect types Gear Assy Armature Assy Brush Assy Motor shroud Assy

Measurement Defect segregation Operation speed simulator Packing Name plate Assy Bush Assy Ring p/f Heater case Assy

Inspection & Maintenance DOJO Safety DOJO

Kakotora Gap detection Drawing symbol & view Step sensing 3S Demo Residual pressure Hidden portion Electric shock

Angle detection Kanban Handling Defect detection Force sensing Fire prevention Heavy weight handling Fire extinguisher PPE’s