“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.
@5S BalaMurugan
[Link] tqmbala@[Link]
Types of OPL
OPL
[Link] 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
[Link] case study sheet :
Educating tackling of an actual problem that happened in the past.
Improvement/
Kaizen sheet
[Link] / Kaizen lesson sheet:
How productivity and quality can be improved in small continual steps.
[Link] tqmbala@[Link]
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.
@5S BalaMurugan
- 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.
[Link] tqmbala@[Link]
One Point Lesson
Sample OPL Sheet
[Link] tqmbala@[Link]
JMA Industries, Sholavandan, Madurai - 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
[Link] [Link] ZZZZZ
ABC Textiles LTD, Mumbai - OPL Sheet
Theme HOUSE KEEPING IMPROVEMENT OPL No :
Location : Location Name Date : 12/03/2016
Type Problem Basic Knowledge Improvement
Do not place half lap material on
machines; it's an incorrect practice.
Lap should only be placed on trolleys like
this.
Prepared by - Approved by - Dept. Status
[Link] [Link] ZZZZZ
ABC Automobiles Ltd, Madurai - OPL Sheet Logo
Plant Process Area / M/C No. OPL Pertains to Doc. Ref No.: DOP
Troubleshooting Basic Knowledge Improvement
@5S BalaMurugan 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
Lean Practitioner | Quality Management Trainer | HRD Professional
[Link] tqmbala@[Link]
[Link]