Navigating Complexity: Challenges in Developing Simulation Models for Sterile Processing

The Sterile Processing Department (SPD) is an essential component of hospitals and healthcare facilities. It ensures the cleanliness, sterility, and proper functioning of medical instruments. A well-designed SPD workflow can improve productivity, reduce operating room (OR) delays, and enhance patient safety. Developing a simulation model for sterile processing is challenging because of the complex interactions between different units, such as decontamination, assembly, sterilization, storage, and case-cart preparation. Moreover, the dynamic nature of the surgical volume, tray requirements, and staffing dynamics further complicate the modeling process. Furthermore, missing instruments, bioburden, and nonfunctional instruments add another layer of complexity. Therefore, the additional tray request from OR personnel results in undue strain on the SPD's inventory of trays and its ability to process dirty trays and instruments. This study focuses on the following challenges: duplicate tray requests, replacement tray needs, tray representation, on-time start pressures, and staff shortages.