One Point Lesson - OPL

At recent moment, I found a term for OPL for TPM which I am not so familiar. Therefore, I dig out some information and summarized as below to keep a reference, share with my readers.

What is OPL?

OPL is the short term of One Point Lesson. A TPM one point lesson is just one of the many tools that can be used to improve knowledge and understanding of the condition and performance of an asset on a day-to-day basis. The approach engages the front-line operations and technicians and encourages them to get involved in the continuous improvement of the asset. By simply passing on good ideas, maintenance interventions can be optimised to ensure there maximum impact on either the performance or condition of the assets. The benefits for implement OPL for workshop are summarized as below,

* Communicates knowledge and skill about the asset amongst members of the team.
* Raises the knowledge and skills of the team in a very short period of time.
* Is used for eliminating problems and for making improvements to the way of working.
* Makes sure that everyone knows about a better way of doing something.
* Makes sure that next time a problem is encountered everyone knows the way to solve it.

Here is the flow of running OPL,

1. One member of the team prepares a sheet, which describes the problem and solution in simple language. It is often illustrated with pictures if possible.
2. The team discuss the 1-point lesson, formally or informally, and incorporate any ideas.
3. The 1-point lesson is approved by the line management to ensure it is appropriate and safe.
4. The 1-point lesson is then published and read by all members of all shift teams.
Individuals are then asked to sign to acknowledge that they have read the 1-point lesson.

OPL should contain the elements,

1. Workshop location (plant, floor, line #)
2. A simply description of the purpose of this OPL
3. Use photographs or diagrams to show before and after sections
4. Who prepared the document? Who approved the document?

Below are the critical points for successfully implement OPL,

* Treat only one piece of knowledge at a time. The TPM approach is about small incremental steps to continuous improvement.
* Use simple clear language. The objects can be clear learned in 5 -10mins.
* Illustrate the idea with pictures or drawings closing to the place which it is applying.
* Make the 1-point lesson available to everyone who need to work on that process.
* Recognise and reward those who share their knowledge.