Case Studies

Lean Healthcare: Sterile Processing Department

Lean Healthcare


The Operating Room was receiving instruments that did not meet quality standards.


Solution: A number of layout and process improvements were implemented based on a 5-day Value Stream Analysis Processsm, which documented the current state, designed the future state, and developed a project plan to manage the improvements. OPS provided on-site implementation support and helped manage the execution of the Implementation Plan, including regular progress reviews with the customer.

Results (First 6 months of implementation)

  • 41% Reduction in Cycle Time
  • 45% Improvement in Quality
  • 100% Improvement in Nurse Satisfaction
  • 200% Improvement in Surgeon Satisfaction
  • 45% Decrease in Replacement Tool Costs
  • 44% Reduction in Agency Staffing Costs

Financial Results

  • Saved more than the cost of the project in the first 3 months of implementation
  • Essentially doubled productivity by reducing lead time without investing any capital or hiring additional staff


  • Improvement in Quality over 75% and it continues to improve everyday
  • 100% reduction in Agency Staffing Costs
  • Sustained Lead Time improvements