Key result
Application of the Six Sigma lean methodology to the surgical instrument sterilization process significantly improved the Sigma value from 4.79 to 5.04 (SMD 0.60), decreasing costs of poor quality.
Why the study?
Operating room management is complex, and the study aimed to assess the impact of Six-Sigma methodology on optimizing surgical instrument sterilization processes.
Observational
No
Standardized Mean Difference: 0.6 (95% CI 0.16–1.04)
Absolute Event Rate: 5.04% vs 4.79%
p-value: p=0.010
The application of Lean Six Sigma methodology to surgical instrument sterilization processes significantly improves process quality, reduces costs, and increases personnel satisfaction.
May reduce sterilization costs and boost satisfaction; leaves open causality and generalizability in prospective trials.
Operating room (OR) management is a complex multidimensional activity combining clinical and managerial aspects. This longitudinal observational study aimed to assess the impact of Six-Sigma methodology to optimize surgical instrument sterilization processes. The project was conducted at the operating theatre of our tertiary regional hospital during the period from July 2021 to December 2022. The project was based on the surgical instrument supply chain analysis. We applied the Six Sigma lean methodology by conducting workshops and practical exercises and by improving the surgical instrument process chain, as well as checking stakeholders' satisfaction. The primary outcome was the analysis of Sigma improvement. Through this supply chain passed 314,552 instruments in 2022 and 22 OR processes were regularly assessed. The initial Sigma value was 4.79 ± 1.02σ, and the final one was 5.04 ± 0.85σ (SMD 0.60, 95%CI 0.16-1.04, p = 0.010). The observed improvement was estimated in approximately $19,729 of cost savings. Regarding personnel satisfaction, 150 questionnaires were answered, and the overall score improved from 6.6 ± 2.2 pts to 7.0 ± 1.9 pts (p = 0.013). In our experience the application of the Lean Six Sigma methodology to the process of handling the surgical instruments from/to the OR was cost-effective, significantly decreased the costs of poor quality and increased internal stakeholder satisfaction.
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Saporito et al. (2023) conducted an observational in Surgical instrument sterilization process. Six Sigma lean methodology vs. Pre-intervention (initial state) was evaluated on Sigma improvement (reduction in defects per million opportunities) (SMD 0.60, 95% CI 0.16-1.04, p=0.010). Application of the Six Sigma lean methodology to the surgical instrument sterilization process significantly improved the Sigma value from 4.79 to 5.04 (SMD 0.60), decreasing costs of poor quality.
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