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Related Experiment Video

Updated: Feb 18, 2026

Optimizing Minimally Invasive Spine Surgery: A Fully 3D CT O-Arm Navigated Workflow in MIS TLIF

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Surgical tray optimization as a simple means to decrease perioperative costs.

James S Farrelly¹, Crystal Clemons², Sherri Witkins²

¹Department of Surgery, Yale University School of Medicine, New Haven, Connecticut.

The Journal of Surgical Research

|November 29, 2017

Summary

Optimizing surgical trays by removing unnecessary instruments significantly reduced costs and processing time in hospitals. This simple microsystem improvement offers substantial savings and operational efficiency.

Keywords:

Cost-effectiveness Health care efficiency Instrument reduction Perioperative management Surgical tray optimization

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Area of Science:

Healthcare Operations
Surgical Services
Cost Reduction Strategies

Background:

US healthcare spending is high, with opportunities for cost savings in hospital operations.
Surgical instrument processing presents a target for reducing unnecessary expenditures.
This study aimed to decrease costs associated with surgical instrument processing.

Purpose of the Study:

To implement and evaluate a surgical tray optimization program.
To reduce the number of instruments processed and associated labor costs.
To identify unnecessary instruments within surgical trays.

Main Methods:

A single-site observational study at an academic medical center.
Standardization and elimination of unnecessary instruments from pediatric surgery trays through multidisciplinary consensus.
Application of the optimization method to other surgical sections including urology, neurosurgery, spine, and orthopedics.

Main Results:

Pediatric surgery section eliminated 39.5% of instruments and nine trays, reducing processing time by 28.7%.
Significant instrument and tray reductions were observed across urology, orthopedics, neurosurgery, and spine sections.
Estimated annual instrument cost avoidance ranged from $53,193 to $531,929.

Conclusions:

Surgical tray optimization is a feasible microsystem improvement for significant hospital cost reduction.
Reduced instrument processing leads to decreased labor, materials costs, and tray weight.
Minimal negative feedback indicates successful implementation and acceptance of optimized trays.