COMPETITION
The Knowledge Development Center
1. Welding Dojo
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2. Maintenance Dojo
The Preventative Maintenance (PM) Dojo is standardizing and improving maintenance performance through continual training in the electrical and mechanical skill of Maintenance Technicians, including the study of maintenance systems, theory, and skill application with manufacturing equipment. Training covers basic electrical, to PLC programming and electrical troubleshooting, as well as mechanical systems of pneumatics, hydraulics, equipment part replacement, and mechanical troubleshooting.
3. Leak Test Dojo
Leak Test is a very important skill at DTTP that complements brazing.
While every brazer tries their best to create a leak-free component, our leak testers carefully scrutinize those same components, ultimately enhancing our ability to put an excellent, leak-free product in the field.
4. Core Skills Dojo
The Core Skills Dojo is a 3-day curriculum that includes:
- Knowledge development of Daikin culture
- 6S and disruption free production
- A basic math evaluation
- Hand/eye coordination testing
- Employee PPE and dress code review
- Safety review of lock out/tag out procedures, ergonomics and an evaluation of attentiveness
- Training in various technical and motor skills such as: screw drill, electrostatic discharge, kitting, coil lacing, wiring, mechanical power press, press operator 101, and first-piece inspection.
At the conclusion of the training personal a one-on-one session is conducted with the employee to evaluate their best fit with current open position.
5. Brazing Dojos
Brazing is the process of joining two metals together with a molten filler metal. The filler metal will have a lower melting point than the two metals being joined together. Copper and aluminum brazing are core competencies to delivering the quality of our products.
“Brazing takes very good hand-eye coordination and excellent eyesight to see the subtle changes in the alloy and the torch flame,” said Director of Process Excellence, Michael Kubiak. “This is a very important skill in manufacturing.”
Brazing was the first skill tested when competitions began in 2014. In February’s Local Skills Competition, brazers were evaluated and scored in the Local Skills Competition by DIL certified trainers on safety, quality, brazing operation technique, and speed. Scores for each category are combined to determine the rank of the brazer.
6. Sheet Metal Dojo
The Sheet Metal Dojo is the entry level of career progression to acquiring a position in Tool and Die. Employees learn blueprint reading, basic press operation, with specific focus on die setting in the sheet metal area. The trainers issue special certification ID badges (passports) for those who pass the 5-day die setter training and subsequent validation of skill and knowledge application in the Genba.
7. Safety Dojo
While not part of the Skills Competition, the training conducted in the Safety Dojo raises awareness to prevent the occurrence, or risk of, injury, danger, or loss while working in Manufacturing. All new hires, regardless of the position they have been recruited into, undergos the 2-hour course as part of their onboarding process. While in the Safety Dojo, employees experience safety awareness through simulations and demonstrations involving many senses including sight, sound, smell, and touch.
8. Tool and Die Dojo
The DTTP Tool & Die department makes dies to stamp out the sheet metal parts and coils that get assembled into our units. Tool & Die also performs preventative maintenance and repair on all dies and tooling. This skill involves reading and understanding blueprints and proper use of heavy equipment to mill a part for a specific intended use.
The Tool & Die Dojo is focused on die set-up, die change-over, and die press operator skills. The competitors will be making a useful part that can be utilized in production after the competition! All competitions are timed, and scored for safety, quality, following process steps, and the fit and function of the final piece made by the competitor.