Application of Lean Methodology for Improved Quality and Efficiency in Operating Room Instrument Availability

Area of Science:

• Surgical Innovation
• Healthcare Operations Management
• Lean Manufacturing in Healthcare

Background:

• Increasing complexity of surgical instrumentation presents challenges in operating room (OR) efficiency and supply chain management.
• Despite advancements, surgical instrument complexity can increase surgical risk and burden supply chains.

Purpose of the Study:

• To develop and validate a Lean 5S approach for improving operating room instrument availability and quality.
• To assess the impact of the Lean 5S intervention on instrument reduction and surgical setup times.

Main Methods:

• A Lean 5S methodology (sort, simplify, sweep, standardize, self-discipline) was implemented and validated.
• The intervention focused on reducing unnecessary instruments and standardizing instrument trays for specific procedures.
• Outcomes measured included the number of instruments, setup time, and cost savings.

Main Results:

• A 70% reduction in surgical instruments for minimally invasive spine surgery (197 to 58 instruments).
• A 37% decrease in setup time (13.1 to 8.2 minutes, p = .0015) was observed.
• The approach was validated on deep brain stimulator cases, showing potential for significant cost savings.

Conclusions:

• Complex surgical procedures present opportunities for substantial waste reduction and quality improvement through Lean methodology.
• Implementing Lean 5S can enhance operating room efficiency, reduce costs, and improve patient care.
• Potential institutional annual cost savings of $2.8 million can be achieved by optimizing surgical instrument management.