ONE-POINT LESSONS (OPL) *)

What is O P L :

¾ is a 5 to 10 minutes (normally take less than 15 minutes) lesson one topic

on one sheet -means only One Point illustrated on a sheet of paper-, as
many senses as possible should be addressed
¾ It must be written As Simple As Possible
¾ The Point or Topic Can Be the Function of Equipment, Installation of Jigs,
Cleaning Method, Types of Lubrication and Methods of Inspection etc.
¾ It Is Generally Prepared by Supervisors or Group Leaders and Sometimes
By Operators.

Types of OPL:

¾ Basic information sheet: essential basic information – practical know-how

and know-how of methods
o Maintenance activities as e.g. filter changing
o Small repair works
o Setting of machine functions
o Cleaning and checking
o Lubricating
¾ Problem case study sheet: teaches how to prevent recurrence of an actual
equipment problem
¾ Improvement / Kaizen lessons study case: describes the approach and
key measures in a successful improvement case study

Why we need OPL?

¾ To pass on better knowledge

¾ Stregthen the understanding for functions of machines and lines
¾ Improve knowledge about maintenance defect prevention

Which method used to deliver OPL?

Use all sense of people: tasting, feeling, smelling, hearing, seeing; the gathering
of information occurs in
¾ 83% by seeing: pictures, sketches, graphs, drawings
¾ 11% by hearing: whistling, rattling, squeaking
¾ 3.5% by smelling: chemicals, smell of fire
¾ 1.5% by feeling: surfaces, roughness, heat
¾ 1% by tasting: sweet, bitter, salty, sour (food industry)

*) Noeradji Prabowo – PQM Consultants, Jakarta 10510, Indonesia

e-mail: np@pqm-iris.co.id or noeradjip@yahoo.com
http://www.pqm-iris.co.id
1/4
Effect of OPL, man keeps in mind

¾ 20% by hearing
¾ 30% by seing
¾ 50% by hearing and seing
¾ 70% of that what he speeks about
¾ 90% of that what he does by himself

Where should OPL happen

¾ At the Gemba / shopfloor / on the machine when possible

¾ In the training center near the shopfloor

When deliver OPL?

¾ before the shift

¾ after the shift
¾ during the shift
¾ during unplanned downtimes

Who should conduct OPL?

¾ Employees on the shop floor Foreman, Supervisor

¾ Employees from the maintenance Electricians, Mechanics
¾ Employees from the technical office Engineers, Technicians

Reference

¾ Productivity Development Team, One-Point Lessons, Productivity Press,

2000

*) Noeradji Prabowo – PQM Consultants, Jakarta 10510, Indonesia

e-mail: np@pqm-iris.co.id or noeradjip@yahoo.com
http://www.pqm-iris.co.id
2/4
*) Noeradji Prabowo – PQM Consultants, Jakarta 10510, Indonesia
e-mail: np@pqm-iris.co.id or noeradjip@yahoo.com
http://www.pqm-iris.co.id
3/4