What are One Point Lessons (OPLs) in Manufacturing?
Consistency is a core principle of building sound manufacturing processes . Consistency is critical for continuous improvement . It helps reduce human error and waste, which is essential for maintaining healthy profits.
However, manufacturing processes struggle to implement quick, practical training, given processes are often complex.
To remedy this, many operations issue one-point lessons. Below, we’ll explain these lessons and how they’re necessary to share essential knowledge with all team members
One-point lessons (OPLs)—sometimes called single-point lessons—are visually rich and concisely written documents that teach operators how to perform a specific action. OPLs are quick to create and easy to consume and are therefore a much-loved and often-used instruction format in factories.??
What are one-point lessons (OPLs)?
One-point lessons (OPLs) are short, visual instructions that guide frontline workers on how to perform a single, relatively small action or task.??
OPLs are closely related to standard operating procedures (SOPs), but the two should not be confused.??
Where SOPs can be long, text-heavy documents, one-point lessons have the following characteristics:??
In short, an OPL should be simple, concise, and precise, so that operators can put its guidelines into practice effortlessly.??
As OPLs deal with very specific actions, they should also be easy to find.??
They should, for example, be hung near the areas they apply to or be categorized according to a machine’s error codes.???
What Are the Objectives of a One-Point Lesson?
In factories and warehouses, OPLs cover a wide range of objectives while always maintaining succinctness
Basic Knowledge
OPLs are simple and effective, giving workers important instructions for important tasks, like cleaning equipment to avoid damage.
Error Prevention
Keep OPLs up-to-date to address safety procedures and concerns, ensuring the safest work environments.
Continuous Improvement
OPLs help express the results of continuous improvement initiatives, serving as guides on instilling Kaizen practices to increase efficiency.
领英推荐
Standardization
Success relies on meeting and maintaining health and safety standards, as OPLs provide employees with clear ways to meet these needs.
Communication and Collaboration
Communication failures waste time and materials, but OPLs outline proper communication channels to improve collaboration and eliminate waste.
Use Cases for One Point Lessons
Manufacturing managers use OPLs across all key areas to achieve autonomous maintenance , lean manufacturing , and just-in-time production . Below are some common OPL use cases.
Troubleshooting
Manufacturing processes involve lots of complicated, error-prone equipment. Managers should create OPLs to address all potential error codes. Then, when a code appears, employees can reference specific documents without delay.
Quality
Maintaining peak production quality requires paying attention to many small details. OPLs build consistent quality assurance practices, such as a guide about product handling or packaging materials correctly. These documents lead to more consistent quality and reduce the likelihood of flaws.
Procedures
OPLs are excellent for spelling out specific tasks and procedures with inflexible rules like equipment operation and maintenance.
Safety
OPLs help enhance safety in everything from equipment operation to on-site uniform requirements.
Communication and Collaboration
Use OPLs to visually promote collaboration by outlining communication hierarchies and establishing a command point at each workstation.
Examples of a One Point Lesson
As stated, OPLs work best with clear visuals with simple text. Below is an example of how to build an OPL to clean a factory machine.
The OPL would display an image of the machine and highlight each part requiring cleaning. From there, build a checklist with simple instructions, ensuring the employee knows exactly when they’ve accomplished the task. Don’t forget the room for key details, like the date, time of cleaning, and employee name.