One Point Lessons (OPLs) are short, visual presentations on a single task that can be explained in about 10 minutes. They are detailed on one or two pages using diagrams, photographs or drawings. OPLs are used to provide vital instructions for tasks at the workplace and are generated and used at the point of need. An example is provided of an OPL created to address frequent stoppages on a production line caused by operators not understanding how to change an empty cleaning fluid drum. The OPL clearly outlines the steps to acknowledge the error message and replace the empty drum. OPLs help improve performance, efficiency and quality by ensuring key work instructions are available when needed.

1. One Point Lessons (OPLs)
www.optimumfx.com

2. Intent of Session
• To understand One Point Lessons
• To explain how these are put together
• To understand the opportunities to use them in
the work environment

3. What are they?
• When we buy something like a mobile phone, there are
usually two user documents:
– A manual – 20 pages or more of detailed text
– A ‘Quick Guide’ – normally one piece of paper with graphics
• We can consider the Standard Operating Procedure as
our ‘manual’, and the One Point Lesson as the ‘Quick
Guide’
• One Point Lesson – the vital information, kept near to
hand

4. What are OPLs
• One Point Lessons are used to explain a single point task at a
work station
• They are short visual presentations on a single point
• They can be explained in about 10 minutes
• Detailed on one or two pages
• Supported by diagrams, photographs, or drawings
• Are generated and used at the point of need

5. OPL Use
In this example, there were frequent
stoppages on a production line when
a machine ran out of cleaning fluid
• The actions needed were to:
– Respond to the error message on the
machine panel
– Remove the empty drum and re-connect
to a full drum of cleaning fluid
– Re-set the machine panel and re-start
• Stoppages were due to:
– Operator not understanding the
message referred to cleaning fluid
– Delays in finding advice on how to action
the message
– Confusion over connection of the new
drum
– Failure to re-set the machine, resulting in
further delays as advice was again
sought from the Team Leader or
colleagues
External Cleaning Systems Lines A & Z
Subject: Changing Cleaning Chemicals Materials:
Gloves, Safety Glasses/Face Shield, Funnel
Health & Safety: See COSHH assessments Nos Carb 4,
23 & 29 for appropriate chemicals
Method: Follow steps 1 - 5
1 When either the detergent or disinfectant drum is empty an
error message will appear on the control panel display for the
external cleaning system.
2 Remove the supply feed tube from the empty drum.
3 Open the new drum and carefully decant any residual
chemical from the old drum to the new one. Ensure that the
new drum does not overflow. Discard the old drum.
4 Replace the supply feed tube.
5 Press the ‘acknowledge’ button on the system control panel
and the system is ready to use again.

6. Identifying Opportunities for OPLs
• Where are the opportunities to use One Point Lessons?
– Quality
– Inventory
– Equipment Operation
– Safety
– Maintenance
– Inspection
– Improvement
• Wherever teams need key information to perform their jobs
• Where this ‘key information’ is missing, a One Point lesson
can be used to provide it

7. About One Point Lessons
• One Point Lessons sharpen job related knowledge and skills
by communicating information about specific problems and
improvements
• Team leaders and members who have acquired special skills
or knowledge can share this with their teammates
• Sharing important information just-in-time
• Improving the team’s performance
• Positively affecting employees’ abilities to perform daily tasks
• Improving cost efficiency and product quality

8. Effective Writing of OPLs
• One A4 sheet if possible, maximum two
• Use photographs and text with arrows – the information needs
to be accessed quickly
• Ensure the subject can be explained in a maximum of 10
minutes – otherwise consider a Standard Operating
Procedure
• Show ‘correct’ and ‘incorrect’ topic photos if possible
• Consider where the information should be displayed – where
the task is performed is best

9. OPL Example

10. OPL Example

11. What If
• Without One Point Lessons we risk:
– Not having the vital knowledge available when required at the workplace
– Delays and errors through individuals not having the correct information
available
– Team Leaders and Managers dealing with frequent interruptions
– Missed opportunities for staff development
• With One Point Lessons we have:
– The vital knowledge for the task visible and acceptable
– Fewer problems for teams and increased efficiency
– Team Leaders and Managers able to concentrate on value-adding
activities
– Development of staff through knowledge and self-reliance