Business case
- 627 bed hospital desired to reduce OR supplies and instrument inventory by 1M
- Desire to eliminate labor and other wastes in supplies and instrument operations
Initial Condition
- Instrument tray accuracy rate less than 78%
- Instrument tray assembly rate averaging 16 min. per case
- Average OR supply case pull time averaging 11 minutes
- Excessive overtime and FTE levels
Target Condition
- Re-allocate 3 FTE’s to enhance constrained areas, reduce supervisory time related to error correction
- Improve instrument accuracy rate to over 95%
- Reduce inventory levels in excess of 1M
- Reduce case cart pull times and decontam process response times
Planned Activities / Intervention
- Hospital Executive team and CSPD management team attended a 2 Day Lean Overview / Leadership class
- CSPD supervisors trained on Lean Overview, 7 Wastes, 5S, and Standardized Work
- Development of roles and responsibilities for medical tower instrument room staff thereby achieving process optimization, and reducing hours of coverage
- Development of visual management, standardized work, and single piece flow in main OR instrument room decontamination process
- Development of Information / Communication Board within CSPD to drive process improvements, Daily management and Policy deployment process
- Development of Kamishibai board for a sustainment tool for auditing improvements, standardized work, and single point lessons.
Achieved Metrics
- Instrument Room Quality Rate increased from 78% to 92%
- Supply case cart accuracy increased from 83% to 87% to date
- Supply case cart pull time reduced form 10min. to 6 min.
- Inventory reduced by 1.1M
- 3 FTE reallocated and overtime eliminated
