An Enhanced Kaizen Event in a Sterile Processing Department of a Rural Hospital: A Case Study

Area of Science:

• Healthcare Management
• Operations Research
• Medical Device Processing

Background:

• Operating Rooms (ORs) are critical revenue centers, heavily reliant on efficient Sterile Processing Departments (SPDs) for surgical tray supply.
• Limited medical literature addresses surgical instrument processing optimization within SPDs.
• SPD workflow inefficiencies can significantly disrupt OR schedules and patient care.

Purpose of the Study:

• To apply an Enhanced Kaizen Event (EKE) methodology to identify and minimize waste in a rural hospital's SPD.
• To develop a systematic approach for improving SPD processes through iterative cycles.
• To enhance the efficiency and safety of surgical instrument sterilization.

Main Methods:

• Implementation of an Enhanced Kaizen Event (EKE) comprising three Plan-Do-Check-Act (PDCA) cycles.
• Focus on progressive improvement from departmental to area and station levels within the SPD.
• Analysis of workflow, layout, and workstation design for waste reduction.

Main Results:

• Achieved a 35% reduction in staff travel distance.
• Eliminated non-value-added steps in the SPD workflow.
• Reduced errors in the sterilization process and prevented cross-contamination of sterile materials.

Conclusions:

• The EKE methodology is effective in streamlining SPD operations and reducing waste.
• Optimized SPD layout and workstation design contribute to improved workflow efficiency.
• Enhanced SPD processes lead to reduced errors, minimized cross-contamination, and support OR scheduling.