One Point Lessons (OPLs)

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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

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

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

OPL UseIn 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, FunnelHealth & Safety: See COSHH assessments Nos Carb 4, 23 & 29 for appropriate chemicalsMethod: 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.

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

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

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

OPL Example

OPL Example

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