OPL

One Point Lesson

- 5S BALAMURUGAN
 What is OPL?

 OPL is a simple yet powerful operational tool used to

educate operators in an organization and improve product /
service quality.

 It normally consists of 80% diagram and 20% words.

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 Types of OPL
OPL
1.Basic Information Sheet :
Providing practical know-how of components, machines, method and maintenance.

 Maintenance activities (Checking, Cleaning, Service) Basic Information

Sheet
 Small repair works

 Setting of machine functions

Problem case
study sheet

2.Problem case study sheet :

Educating tackling of an actual problem that happened in the past.
Improvement/
Kaizen sheet

3.Improvement / Kaizen lesson sheet:

How productivity and quality can be improved in small continual steps.

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 Why OPL is required?

Achieving single When an important message To pass on better Develop clear learning
standard of work must be communicated and knowledge. process, machine and
across operators & understood. the line for the operator.
shifts.

Such an understanding will also reduce defects by preventive maintenance of defects.

© 5S BALAMURUGAN
 Key Points to remember when preparing OPL's

OPL Show DO's, Don’ts and Right,

Wrong photos.

Ensure the subject can be explained

in a maximum of 10 mins.
Use photos, texts and arrows -
The information needs to be
accessed quickly.
Only one point illustrated
on a single sheet of paper
It must be written as simple
as possible.

© Sholavandan BALAMURUGAN
 Benefits of - OPL

OPL easily share important OPL improves the team’s

information just-in-time. performance.

People who have acquired Improves cost efficiency,

special skills / knowledge product quality and work
can share with others culture.
through OPL.

OPL sharpen job-related Positively affecting employee's

knowledge and skills by abilities to perform daily tasks.
communicating information about
specific problems and improvements.

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One Point Lesson

Examples
 ABC Textiles LTD - OPL Sheet
Theme HOUSE KEEPING IMPROVEMENT OPL No :
Location : Location Name Date : 12/03/2016
Type Problem Basic Knowledge Improvement

Half laps should not be placed on

machines. It affects housekeeping .

Like this, it should be placed only on

trolleys.

Prepared by - Approved by - Dept. Status

Mr.XXXXXX Mr.YYYYY ZZZZZ

 XYZ Industries - OPL Sheet
Theme TO PREVENT FINGER MARK IN COMPONENTS OPL No :
Location : PACKING Date : 03/12/2016
Type Problem Basic Knowledge Improvement

Finger mark will immerge on the surface of

the component

Use of hand gloves will reduce defect due to

finger mark.

Prepared by - Approved by - Dept. Status

Mr.XXXXXX Mr.YYYYY ZZZZZ

 ABC LTD, CHENNAI - ONE POINT LESSON Logo

Plant Process Area / M/C No. OPL Pertains to Doc. Ref No.: DOP
Troubleshooting Basic Knowledge Improvement

TITLE
Sample
Format

Photo Content

Warehouse Cutting Stamping Welding Painting Assemble Testing Despatch

Prepared By Approved By Format Ref No. : Issue No : Isuue Date File Destination Frequency : D.O.R
As & When As & When
required required
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© 5S Balamurugan
BSc(CS).,MBA.,MA(PM&IR).,MSc(Psy).,PHRM.,
Lean Management Professional
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balamuruganm21@gmail.com