Redesigning an airway cart using lean methodology

Area of Science:

• Anesthesiology
• Healthcare Operations Management
• Quality Improvement Science

Background:

• Difficult airway management requires readily accessible and organized equipment.
• Inefficient storage and transport of difficult airway equipment can delay critical interventions.
• Lean methodology offers a framework for optimizing healthcare processes.

Purpose of the Study:

• To enhance the efficiency of difficult airway management equipment transport and setup using lean methodology.
• To redesign the difficult airway cart through the application of the 5S framework.

Main Methods:

• The 5S (sort, set in order, sweep, standardize, sustain) methodology was applied to redesign the difficult airway cart.
• Simulations of difficult airway scenarios were used to compare the redesigned cart with previous storage methods.
• Key metrics included equipment quantity, cost, retrieval/setup time, walking distance, and setup defect rates.

Main Results:

• Equipment storage was consolidated from 4 locations to a single cart, reducing total pieces by 89% and disposable costs by 81%.
• Simulations showed a 39% reduction in overall equipment setup time and a 77% reduction in non-value-added setup time.
• Walking distance for equipment retrieval decreased by 74% with no change in setup defect rates.

Conclusions:

• Implementing lean methodology (5S) effectively streamlined difficult airway equipment management.
• The redesigned single cart, optimized for use frequency, significantly reduced setup time and physical exertion.
• This approach enhances preparedness and efficiency in managing difficult airway scenarios.