In 2010, DNKI went in for a major Factory Expansion for New Products line from TKM

During this time, we encountered Quality Crisis Management situation: Compromise is not an Option
[1] The Inception of DOJO at DNKI
Overview of Systematic Approach to inculcate Quality Sense
When it comes to quality, compromise is not an option. That's what the upper management of DNKI (DENSO Kirloskar Industries Pvt. Ltd.) believed when they faced a major setback in 2011. The company resumed its efforts to restore quality following the DENSO methodology, when Quality Issue occurred. DNKI started working on Quality Issues to re-achieve Quality through DENSO Way
In 2009, factory expansion began to accommodate major project of Toyota - ETIOS. Launched in 2010 Dec, Etios gave a boost to the morale and hopes to DNKI for expanding the business in INDIAN market. However, this happiness was short lived as we got 2 Major Field claims for the newly launched vehicle in Sep & Dec’ 2011.

1st Field claim: Sep’ 2011 – Early corrosion in Evaporator and Condenser due to Tube Clad Material reverse by supplier, which resulted in leakage. Further, another issue of electric fan screw loose problem.
Back-to-back 2 issues of Vehicle to call back put DNKI on a highly embarrassing situation. The management recognized it as a big blow to the brand image of DENSO “Quality Must” Philosophy.
Identifying the Root cause
Management conducted deep analysis to find the root-cause and identified that it was Material Change at Supplier end without discussing with DN management, and secondly the manpower to do the Quality Check is not skilled.
In case of Electric Fan issue, it was the sensing skill to use the Air Driver was lacking and no understanding of full function of the product. Though there was a skill training available, there was no “DOJO” and DNKI operates with 70% flexible manpower.

Turnover of manpower was leading to some trained and some not as there is no DOJO. So, in quest of attaining “0” Quality issue DNKI started full-fledged DOJO. For over the last 7 years DNKI Dojo is one among the best in the Toyota Group of Companies at Bengaluru and benchmarked to improve their DOJO. Further, to improve the supplier quality, DNKI studied their system and improved their quality standards by deep penetration by sustained effort. With the current robust Quality Management System, we have been managing our Quality standards up to customer satisfaction and we have been receiving awards from most of the customers like TKM, Honda, Maruti Suzuki and BMW.