DOJO Training Curriculum

Time Process

9:00am to About Company

11:00am

11:00am to Tea Break

11:15am

11:15am to Shop floor

1:00pm overview

1:00pm to Lunch
1:30pm
 1:30pm to Safety
3:00pm
DAY-1

3:00pm to Tea Break

3:15pm
 Material
3:15pm to movement and
4:00pm Color code of
bins

4:00pm to 5S
5:00pm

5:00 pm to 5:30 Review

pm

9:00am to 5S
11:00am
9:00am to 5S
11:00am

11:00am to Tea Break

11:15am
11:15pm to Molding process
1.00pm
Day-2

1:00pm to Lunch
1:30pm
 Product
information

1:30pm to
3:00pm

Product gallary

3:00pm to Tea Break

3:15pm

Packing
3:15pm to
 Packing
3:15pm to standard / Part
5:00pm handling

5:00 pm to 5:30 Review

pm
 Raw material
handling

9:00am to
11:00am

Molding defects

11:00am to Tea Break

11:15am

Assembly /
 11:15am to Assembly /
finishing
1:00pm overview

1:00pm to Lunch
1:30pm

Day-3
Day-3

1:30 pm to 3:00 Mould loading /

unloading
pm process

3:00pm to Tea Break

3.15pm

3:15pm to Raw materiai

04:15pm issue method
 About machine
maintenance

04:15pm to
05:00pm
 04:15pm to
05:00pm

Production
( GEMBA) RULES

5:00 pm to 5:30 Review

pm

09:00am to Review of work

10:00am

10:00am to Assembly visit

11:00am
11:00am to Tea Break
11.15am

11:15am to Overall factory

01:00pm visit

01:00pm to Lunch Break

01.30pm
Day-4
01:30pm to molding shop
03:00pm floor
Day-4
01:30pm to molding shop
03:00pm floor
03:00pm to
03.15pm Tea Break

03:15pm to Review with

03.45pm Plant Head

03:45pm to Written test and

05.00pm evalution

05:00pm to End of training

05.30pm session
 DOJO Training Curriculum
Sub-process Method Location

a. About company (Declaration by New Joinee)

b. Customer name--Maruti , Honda , Nissan ,GM .

c. discipline , tea / lunch time , dress code / duty hrs. , attandance system

d. gate entry checking sytem ppt and

physical Class room
verification
e. gate entry should be 10 min before on duty times and take releving from
your releiver
f. use canteen area as per defined time by deptt.

g. prohibited things , like-tobacco , cigeratte , bidi , gutkha, Declaration

a. process :- molding , press shop , assembly , cnc wire bending

b. Overview of moulding mc during running / cleaning near mc area A/V Class room

c. 3 types bins .-(green , red , yellow) , referance sample box , led tv

a. Difference types of Fire extinguisher uses

b. Loose wire
c. Robot safety
ppt and
d. working safety physical Class room
verification
e. safety equipments
f. man safety
g. material safety
Empty bins/box kept near machine as its assigned place.

Part packed in standard packing.

Keep the bins/box near machine.

After the putting the batch card, bins/boxes shall transfer to after moulding
area. ppt and
physical Class room
verification
Than after bins/boxes transferred to store.

c. Green bin : for ok parts, Yellow bin : For 5 shot, Red bin : for reject parts

f., Black bin : For internal transist, small orange bin:--for honda supply

g:- gray jumbo bin:--for after sorting of 5 shots (ok parts) --transfer to
assembly, orange jumbo bins:--for plated parts sohna unit.

a. Seri ( sorting )-------------------

A/V Class room
b. Saiton ( Set in order )-----------------

Review of first day training Oral class room

c. Seiso ( Shine )----------------------------

d. Seiketshu ( Standarization )---------- A/V Class room

 A/V Class room

e. Shitshuke ( Descipline )-----------------

a. Knowledge about injection moulding machine

b. injection unit , clamp unit , hopper , barrel , fixed platen , moving platen ,
tie bar

c. auxillary equipment :-hopper dryer , mtc , hrtc ,chiller , cooling tower ,

robot and Oven for material preheating

d. put raw material in hopper , then material comes into barrel

e. mold load , mold locking , injection with pressure , cooling time , charging
time ,

f. holding time , mold open , part eject , pick part manually and do visual
inspection as per wi

g. detail about 5 shot system .(how it works) and online fixture (pocket
tuner, handle side door trim, case pull handle etc.)

A/V Class room

h. put part into standard packing material (polythene / foam) , then kept
into green bin , blue box , green box as per requirement

i. part will check by quality at every hour , put batch card with operator
name in final bin / box (part weight check in every 2hrs.)
j. quailty will put stamp on batch card , bin / box will move to after molding
area. dimension check , gauge check,first part approval by quality , last part
approval , signed reference sample

k. wip store will pick all parts from after molding area

l. auxillary equipment :-hopper dryer , mtc , hrtc ,chiller , cooling tower ,

robot

m. hourly prod. Sheet , start up check sheet daily., msp , wi

n. lux level , batch card , mold camera system , quality alart

a. Part visual inspection , training about different types of parts

b. Handles , garnish , holder , clamps , ip parts , bumpers, column hole ,

clips ppt and
physical Class room
verification
c. painting parts , plated parts , bins (inhouse )

d. different types of color :--5pk , p4z ,v6n , xba , 6gs , 4vs , t01 , etc

a. holders, clamps , Garnish sash bracket , Garnish IP parts,

b. Garnish IP DRVR INSIDE , pocket tuner , RR van handle

c. Bazel , clips , handle , Knob. Visual Class room
d. Garnish center lower , piller , Grip park lever

e. Power press parts, Wire bending parts,Paint shop parts,Assembly parts

a. different types of packing std.

b. greeen bin , polythene (different sizes) , epdm foam for part packing as
per requirement
c. blue box for defined parts , green box for defined parts
d. part should be kept in bin / box , as per quantity entry on batch card
ppt and
 ppt and
physical Class room
e. part should kept in proper bin/ box , don,t use burst , wear and tear verification
boxes and bins
f. part should be kept as per defined quantitiy
g. avoid over flow of packing at bins / boxes
h. box / bins stacking should be proper
i. bins / box height should not more than 6 fit

Review of second day training Oral class room

a. Raw material : PP,LDPE, ABS,PC , POM , PA6,66 , HDPE, TPE, LLDPE.

b. Raw material / master batch mixing with the help of mixer ppt and
physical Class room
verification
c. hopper dryer /daybin cleaning before the change of the colour

d. Hopper dryer temp. set according to material

a. short moulding
b. burn marks, silver stricks, flash , dent mark
ppt and
c. oil marks , gas marks physical Class room
verification
d. Ejector pin marks , weld line , air vent ,
e. Shrinkage , sink mark , flow mark, shining

a. finish goods received from store .

b. deflashing of the part / clip assembly / pad assembly / foam paste

c . Work should be as per wi , quality alart , running part video ,

d. ensure jumbo red bin on working table

e. small blue for keeping smaal bop parts
DOJO
 DOJO
f. if any part having poka yoke (online fixture / torque gun ) during woring Theory and practical
then use it practical room

g. at working table , one side should green bin with parts and other side
should blue bin for supply

h. Put batch card on bin (qc ok , stamp no.)

i. Visual inspection
j. PDI Inspection / ifc stage
k. Dispatch
a.pick mold from identify mold rack as per moldloading plan
b. put eye bolt and lift with help of crane
c. remove wrapping polythene from mold
d. now move mold to between mc platen , make center of nozzle and sprue DOJO
bush A/V practical
room
e. making locking and then clamp mold with studs and mods

f. make connection of hrtc , mtc ,cooling pipes , hydraulic pies etc.

g, same vice versa will follow for mold unloading

a. make requition slip , way no , material name , required quantity ,

b. send to store , required material issue to molding from store, material

will move by trolly
c. materail will kept in molding ,(identified area). ppt and
physical Class room
d. required material preheat in oven according to mold loading plan , read verification
oven wi , temp.
e. make an entry in material prheating record ragister.
f . mix master batch with mixture if required , then feed in mc hopper

a. Basic Knowledge of hydraulic oil / lubrication oil chechking

b. nozzle heater problem
c. front gate error
d. mold not close / ejctor not functioning ppt and
physical Shop floor
e. main motor not statred verification
f. information of different types of alarms
g. information about main gate / rear gate safety
h. abnormal noise in mc
i. alarm due to intelink system
a. rm store
b. iqc
c. molding
d. inprocess qa
e. after molding ppt and DOJO
f. wip store physical practical
g. assembly / fininshing verification room
h. inprocess qa
i. ifc (if applicable)
j. pdi
k . Dispatch
Review of third day training Oral class room

a. review of all 3 days work (training of all 3 days) Class room

Practical

a. Assembly visit (overall view as per theoritical training given) Shop floor

a. Overall factory visit (store , wip , power press , cnc wire bending , quality , Practical Shop floor
rm store etc)

a. molding shop floor for simulation of theory work vs videos Practical Shop floor
a. molding shop floor for simulation of theory work vs videos Practical Shop floor

Meeting with Plant Head Practical Shop floor

a. Test for level 1 Written Exam

class room
a. end of training session and level 1 acheiver shall be send on shop floor
for OJT (two weeks). After two weeks evaluation shall be done. Feed back Paper marking
form.
 Trainer

Mr. Gulshan

Mr. Kapil/Pankaj
 Vishal
Dhawan/Ashutosh
Mr. Kapil/Pankaj

Vishal
Dhawan/Ashutosh

Vishal
Dhawan/Ashutosh

Vishal
Dhawan/Ashutosh
 Vishal
Dhawan/Ashutosh
 Vishal
Dhawan/Ashutosh
Mr. Kapil/Pankaj

Mr. Kapil
Mr. Manoj

Mr. Manoj
 Mr. Pankaj

Mr. Kapil/Pankaj
Mr. Manoj
Mr. Pankaj

Mr. Kapil
Mr. Ajay
Mr. Manoj

Mr. Manoj

Mr. Manoj

Mr. Pankaj

Mr. Kapil
Mr. Kapil

Mr. kapil
 DOJO Practical training room
S.No. Topic Display
Material Handling And FIFO

WI for material identification

1 Store Awareness
Differet material bag cutting

WI for OVEN

Machine start up check sheet

Raw material pre heating record

Check sheet mould loading

2 Moulding Awareness Check sheet mould Unloading

Material detail

Master batch detail

IMM detail parts pic

Model of IMM machine

Degating and deflashing Practice

Rejection - Moulding sheet

Inspection DOJO-In process QPCR Format
3 awareness
FPA and LPA sheet

Hold material register

Clip insertion in part

Child Part identification (practical)

4 Assembly Station Part defect indentification (practical)

Hand movement practice (different part fitting in foam)

Skill matrix display (name with experience)

Online PDI check sheet

WI for Final Inspection

Bin Identification Tag

5 Final Inspection Awarenes
5 Final Inspection Awarenes
Defet awareness Ok and NG part display)

4 M Change procedure

4 M Tracking Sheet

Abnormal Situations

Mould in display (two half)

Fixture in display

6 Maintainance DOJO Parts of IMM

01:30pm to About
03:00pm mold
a. information about 2 plate mold, 3 plate mold , hot runner mold

b.information about core and cavity

c. information about etching surface and gloss surface

d. information about guide puller / guide bush

e. overview of mold / through video

f. oil / greasing of mold

g. font side view / top side view / back side view of mold

h. information of ejector pins , taper lifter , taper ejctor

i. calender maring , material marking cavity marking

 DOJO Mr.
Practical practical Santosh
room