Surgical Tray Optimization and Efficiency: The Impact of a Novel Sealed Sterile Container and Instrument Tray...

As bundle payments have begun focusing on orthopaedic procedures, particularly total knee arthroplasties (TKAs), surgeons and hospitals have evaluated methods for improving efficiency. Few studies have investigated the impact of novel, sealed-container and instrument-tray technology on turnover and costs. Therefore, the purpose of this study was to compare traditional and sealed container-sterilized TKA surgical trays by: 1) investigating the setup and clean-down time in the operating room (OR); 2) examining trays processing time in central sterile supply (CS); and 3) estimating OR and CS costs and waste produced.

An interdisciplinary team determined points throughout a TKA tray single-case life cycle that could cause variations in turnover time. The times were recorded for two different TKA tray configurations. Process A utilized instruments housed in vendor trays that were "blue" wrap sterilized, while Process B employed optimized trays that were sealed container-sterilized. Times were recorded during preoperative setup and postoperative clean down in the OR and CS. Reductions in mean OR or CS times were used to estimate cost savings. Wastes were analyzed for each method. Statistical analyses using Student t-tests were used to determine statistical differences and a p-value of less than 0.05 was considered significant.

Overall, the use of optimized trays and sealed sterilization containers reduced the turnover time by 57 minutes and the number of trays by a mean of three. OR and CS processing yearly savings were estimated to be $249,245. Waste disposal was an estimated 10,590 ounces and 450 ounces for traditional and sealed containers, respectively.

Novel sealed sterilization containers demonstrated increased efficiency in the total turnover time of TKA trays. This is important for surgeons participating in bundle payments who perform surgery in a hospital and ambulatory surgery center. Reduced turnover time could potentially increase case load and decrease the need for extra instrumentation or loaner trays. This simple means of increasing efficiency could be used as a model for surgeons wishing to streamline surgical trays and reduce costs.