{"id":1640,"date":"2025-12-28T17:38:41","date_gmt":"2025-12-28T12:08:41","guid":{"rendered":"https:\/\/singhamarpreet.com\/?p=1640"},"modified":"2025-12-28T17:38:42","modified_gmt":"2025-12-28T12:08:42","slug":"why-set-up-a-dojo","status":"publish","type":"post","link":"https:\/\/singhamarpreet.com\/index.php\/2025\/12\/28\/why-set-up-a-dojo\/","title":{"rendered":"Why Set Up a DOJO?"},"content":{"rendered":"\n<p>A DOJO Training Area is a hands-on learning space for operators or engineers. It comes from Toyota and helps teams practice skills safely before real work. A DOJO teaches operators to get familiar with tools and techniques used on the shop floor, avoiding costly mistakes and producing great quality results.<a href=\"https:\/\/www.scribd.com\/document\/911681033\/DOJO-Manual-Revised-101-204\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b\u200b<\/p>\n\n\n\n<p>New workers often make errors on the shop floor, causing waste or delays. A DOJO lets them train on fake setups without risk. It builds muscle memory for key steps and techniques. Plants see 20-30% less rework after DOJO use. Operators learn shop floor tools hands-on, so they feel ready from day one.<a href=\"https:\/\/www.tetrahedron.in\/dojo-training\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a><br><\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"space-and-location-needs\">Space and Location Needs<\/h2>\n\n\n\n<p>Pick a spot near the work area\u201410&#215;15 feet works for 4-6 work stations. Use open space for quick access.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Floor: Mark lines with tape for safety zones.<\/li>\n\n\n\n<li>Walls: Add mirrors to watch your form.<\/li>\n\n\n\n<li>Lighting: Bright LED lights, no shadows.<br>Cost: 2-5 lakh rupees to start.<a href=\"https:\/\/www.tetrahedron.in\/dojo-training-center\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"key-tools-and-setup-for-each-station\">Key Tools and Setup for Each Station<\/h2>\n\n\n\n<p>Build 4-6 stations, one per skill. Use cheap demo items, not real parts. Run 1-hour sessions daily.<a rel=\"noreferrer noopener\" target=\"_blank\" href=\"https:\/\/www.scribd.com\/document\/911681033\/DOJO-Manual-Revised-101-204\"><\/a>\u200b<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Station 1: Paste Application<\/h2>\n\n\n\n<p>Teaches even paste on boards.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tools: Manual printer (50k rupees), demo stencil, squeegee, test boards, paste pots.<\/li>\n\n\n\n<li>Setup: Table with alignment jig. Apply paste, wipe clean, check even layer.<\/li>\n\n\n\n<li>Practice: 10 boards per person\u2014 Operators get familiar with solder paste printing process and it also helps them to even set up automatic printer more effectively.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Station 2: Part Placement<\/h2>\n\n\n\n<p>For placing small components on solder paste.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tools: Tweezers set, magnifying lamp (10k), feeder trays with fake parts.<\/li>\n\n\n\n<li>Setup: Board holder at elbow height. Pick from tray, place on spots.<\/li>\n\n\n\n<li>Practice: Time 50 parts\u2014aim under 5 seconds each. This helps operators master precise handling of the components and also visualise how an actual SMT machine works.\u200b<a href=\"https:\/\/www.allpcb.com\/blog\/pcb-assembly\/smt-assembly-for-beginners-a-step-by-step-guide-for-electronic-hobbyists.html\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Station 3: Heating Demo Station<\/h2>\n\n\n\n<p>Shows heating to set paste (no real oven).<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tools: Hot plate or small model (20k), timer, soldering air gun.<\/li>\n\n\n\n<li>Setup: Track with fan heating. Run board through heat zones and melt the solder paste, understanding how soldering works.<\/li>\n\n\n\n<li>Practice: Check joints, no burns. Helps operators to understand solder paste behaviour and how paste is converted into a good solder joint\u200b.\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Station 4: Wave Process Station<\/h2>\n\n\n\n<p>For understanding through hole soldering .<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tools: Mini pot (30k) or pump setup, flux spray bottle, conveyor jig.<\/li>\n\n\n\n<li>Setup: Flux spray zone, preheater, mini pot. Solder through hole components on a mini pot.<\/li>\n\n\n\n<li>Practice: 20 boards\u2014clean joints, no bridges. Clean waste often. Practice avoids bridge defects that scrap whole batches.<a href=\"https:\/\/leadsintec.com\/wave-soldering-operation-guide-for-pcb-assembly\/\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Station 5: Hand Soldering Station<\/h2>\n\n\n\n<p>For soldering components those cannot be soldered using wave soldering or needs to be reworked.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tools: Iron kit (5k), tips, flux pen, clean wick.<\/li>\n\n\n\n<li>Setup: ESD Safe mat, fume extractor, parts tray.<\/li>\n\n\n\n<li>Practice: 50 joints\u2014clean tip, right temp, 2-3 sec per pin. Builds steady hands to skip rework on the floor.<a href=\"https:\/\/www.raypcb.com\/smt-step-soldering\/\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Station 6: Check Station<\/h2>\n\n\n\n<p>Final looks with tools.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Tools: Magnifier, scope (15k), light box, defective boards.<\/li>\n\n\n\n<li>Setup: Checklist board. Spot bad joints, missing items.<\/li>\n\n\n\n<li>Practice: Various inspectors inspect same faulty product and prepare a report. The report must co-relate.  Trained operators here means top quality inspection every time on the floor.\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"step-by-step-setup-guide\">Step-by-Step Setup Guide<\/h2>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong>Plan Stations<\/strong>: Match to shop floor steps. List 5-10 common errors per process.<a href=\"https:\/\/www.scribd.com\/document\/911681033\/DOJO-Manual-Revised-101-204\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n\n\n\n<li><strong>Buy Basics<\/strong>: 2-3 lakh for tools (local sellers). Use scrap demo items.<a href=\"https:\/\/www.tetrahedron.in\/dojo-training\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n\n\n\n<li><strong>Build Layout<\/strong>: Tape floor grid. Add safety signs, tool racks on walls. Height: standing work tables.\u200b<a href=\"https:\/\/www.tetrahedron.in\/dojo-training\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n\n\n\n<li><strong>Make Guides<\/strong>: Photos + steps on boards (e.g., &#8220;Even layer, no clumps&#8221;).<a href=\"https:\/\/www.scribd.com\/document\/911681033\/DOJO-Manual-Revised-101-204\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n\n\n\n<li><strong>Test Run<\/strong>: Train leaders first. Time full flow through all stations.\u200b<\/li>\n\n\n\n<li><strong>Daily Use<\/strong>: 30-min warm-up. Groups of 4 rotate. Track scores.<a href=\"https:\/\/www.toyotabharat.com\/documents\/toyota-in-india\/environment\/sustainability_report13_fe.pdf\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b\u200b<\/li>\n<\/ol>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"training-flow-example\">Training Flow Example<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Week 1<\/strong>: Solder paste printing, component placement and reflow soldering.<\/li>\n\n\n\n<li><strong>Week 2<\/strong>: Understanding wave soldering and rework.<\/li>\n\n\n\n<li><strong>Week 3 <\/strong>: Final inspection process and repeatability.<\/li>\n\n\n\n<li>Goal: New operator hits 80% speed\/quality in 40 hours. DOJO makes them pros at shop floor tools fast.<a href=\"https:\/\/www.uniqueskill.in\/PCB-assembly-operator.html\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"maintenance-and-tips\">Maintenance and Tips<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Clean daily: Wipe tools, check temperature on the soldering iron, hot plate etc.<\/li>\n\n\n\n<li>Update: Add new items yearly as per the feedback from shop floor.<\/li>\n\n\n\n<li>Measure: Before\/after tests show 25% faster work, fewer mistakes.<\/li>\n\n\n\n<li>Safety: Gloves, goggles, no loose clothes.<a href=\"https:\/\/mechminds.co.in\/dojo-training-implementation\/\" target=\"_blank\" rel=\"noreferrer noopener\"><\/a>\u200b<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"benefits-of-dojo-training\">Benefits of DOJO Training<\/h2>\n\n\n\n<p>DOJO helps operators get familiar with shop floor tools and techniques in a safe spot. It avoids costly mistakes like bad joints or waste that hit profits hard. Operators produce great quality results right away\u2014less scrap, faster output, happy customers. Plants hit zero-error goals easier.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>A DOJO Training Area is a hands-on learning space for operators or engineers. It comes from Toyota and helps teams practice skills safely before real work. A DOJO teaches operators to get familiar with tools and techniques used on the shop floor, avoiding costly mistakes and producing great quality results.\u200b\u200b New workers often make errors [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[],"class_list":["post-1640","post","type-post","status-publish","format-standard","hentry","category-uncategorized"],"_links":{"self":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts\/1640","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/comments?post=1640"}],"version-history":[{"count":1,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts\/1640\/revisions"}],"predecessor-version":[{"id":1641,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/posts\/1640\/revisions\/1641"}],"wp:attachment":[{"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/media?parent=1640"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/categories?post=1640"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/singhamarpreet.com\/index.php\/wp-json\/wp\/v2\/tags?post=1640"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}