As an operator or manager, you have probably heard of them – or are already using them: One Point Lessons (OPLs). In this blog, we explain how One Point Lessons add value to your organization and what a good OPL looks like.
What are One Point Lessons?
One Point Lessons are short, visual instructions designed to quickly and clearly communicate a single specific topic – such as a safety guideline, a maintenance task, or a quality control check. These lessons are commonly used in production environments as part of Total Productive Maintenance (TPM). OPLs are extremely valuable for operators, but they are also a powerful tool for management to promote continuous improvement. A good One Point Lesson is concise, easy to understand, and directly applicable on the shop floor.
Why are One Point Lessons important in factories?
One Point Lessons add value across various departments in a factory. For operators, OPLs offer practical knowledge in just a few minutes, often supported by photos or other visuals. Examples include lessons on how to prevent malfunctions, properly maintain a machine, or recognize process deviations.
For management, OPLs are an effective tool to promote standardization and continuous improvement. They support knowledge transfer – especially to new or temporary employees – and foster a culture of responsibility and on-the-job learning.
How do you create a clear One Point Lesson?
A clear One Point Lesson is short, visual, and covers one specific topic, such as safety, maintenance, or quality control. Start by defining a clear goal and ask yourself: What should the reader learn or better understand? Keep the content focused on one topic to avoid confusion. Use plain language, avoid jargon where possible, and support the lesson with real-world photos or videos. For instance, show both the “wrong situation” and the “correct method” to provide a complete picture. Keep the text brief (no more than half a page), so the lesson can be completed and understood in under five minutes. Wrap up with a short checklist or summary, and involve operators in the creation process to ensure practical relevance.
One Point Lesson template
If you want to start using One Point Lessons in your organization, it is a good idea to use a template that includes all essential components. Here is an example of what that template might look like:
One Point Lesson (OPL)
Title:
Department/Machine:
Lesson objective: (What will be learned?)
Date:
Prepared by:
Approved by:
Topic
(Brief description of the problem or task)
Incorrect method / Risk
(Photo or drawing + short explanation)
Correct method / Solution
(Photo or drawing + short explanation)
Key points to remember
- Point 1
- Point 2
Employee signature after explanation:
Example of a good One Point Lesson
In a production environment, there are many actions and processes for which One Point Lessons can be created. Here is an example focused on a maintenance procedure:
One Point Lesson (OPL)
Title: Proper cleaning of a transport sensor
Department/Machine: Packaging – conveyor belt 3
Lesson objective: Prevent faulty stops due to a dirty sensor
Date: June 6, 2025
Prepared by: J. de Vries
Approved by: P. Janssen
Topic:
The optical sensor at the end of the packaging line detects boxes. Dirt buildup causes errors and downtime.
Incorrect method / Risk:
Cleaning the sensor with a wet cloth while the machine is running.
Risk: Short circuit or incorrect detection.
Correct method / Solution:
- Turn off the machine using the main switch.
- Clean the sensor with a dry, lint-free cloth.
- If needed, lightly moisten the cloth with an alcohol solution.
- Visually check that the lens is clean.
Key points to remember:
- Never clean with water or while the machine is running.
- Clean at least once per shift.
Employee signature after explanation:
Types of instructions for an OPL
One Point Lessons can serve various purposes. In factories, OPLs are often used to support employees’ basic knowledge, ensure safety on the shop floor, and share lessons from past case studies.
Supporting employees’ basic knowledge
Standard procedures, terms, or tasks can be better explained using OPLs. These may involve routine duties or infrequent scenarios. For example, an OPL could explain how to check the oil levels in a hydraulic system, using a step-by-step guide with visuals and a clear objective.
Ensuring workplace safety
Safety always comes first. OPLs are highly recommended to prevent hazardous situations and promote safe behaviour. One useful topic is how to correctly wear personal protective equipment (PPE). Include instructions on required gear, why it is necessary, and the risks of non-compliance — supported with illustrative photos.
Lessons from past case studies
Some of the most powerful lessons come from past mistakes or near-misses. To avoid repeat incidents, you can create OPLs based on these case studies. Show what went wrong and turn it into a learning moment for both operators and management. Also show the correct approach to help prevent future accidents.
Create and manage One Point Lessons with the EZ-GO platform
The EZ-GO platform supports One Point Lessons by simplifying the digital creation, storage, and sharing of knowledge on the shop floor. Operators can easily create OPLs with photos, videos, and short texts using a tablet or smartphone. Thanks to centralized storage, all lessons are always up-to-date and instantly accessible. OPLs can also be linked to specific machines or processes, ensuring that relevant information is always available in the right context – enhancing safety, quality, and efficiency.