Optimising theatre utilisation through Lean Six Sigma: A model for sustainable theatre utilisation improvement

This quality improvement study was undertaken in the ophthalmology theatres at the Western Eye Hospital, Imperial College Healthcare NHS Trust, to address reduced capped theatre utilisation during the COVID-19 recovery period. Baseline utilisation was 75.8%, below the national Getting It Right First Time target of 85% for theatre touchtime utilisation by 2024/25. The aim was to identify the causes of underperformance and implement targeted interventions to improve theatre efficiency.

A Lean Six Sigma DMAIC (Define, Measure, Analyse, Improve, Control) framework was used as the study design. Targeted interventions included increasing pre-assessment capacity to reduce under-booking, improving scheduling processes, reducing early finishes, and carrying out structured daily reviews of implant and equipment availability to minimise on-the-day cancellations. Multiple regression, factorial Design of Experiments, process capability analysis, Plan-Do-Study-Act cycles, and Statistical Process Control were used to analyse variation, test changes, and monitor performance.

The Analyse phase showed that early finishes, under-booking, and limited pre-assessment capacity were the main drivers of low utilisation, rather than commonly assumed factors such as late starts. Following the introduction of targeted interventions, capped theatre utilisation improved from 75.8% to 81%. Continuous monitoring through Plan-Do-Study-Act cycles and Statistical Process Control supported stability and informed further refinements.

This project shows that combining Lean Six Sigma methodology with advanced statistical analysis can deliver measurable improvements in theatre utilisation. The findings challenged long-held assumptions about the causes of inefficiency and highlight the importance of optimising scheduling processes and pre-assessment capacity. The model offers a transferable, scalable approach for other units aiming to enhance theatre efficiency and achieve sustainable operational improvements.