Houston Methodist Operating Room and Procedural Area Supply Expiration Waste Reduction Kaizen

The First System Level Kaizen Catapults Houston Methodist to Prevent Millions of Dollars in Procedural Area Expiration Waste across seven hospitals in 2023. During FY 2022, there was $3.1 million in Operating Room expiration waste. The team strives to reduce 2023 OR Expiration Waste dollar value by 33% (Attainable Goal ≤ $168,338 per month) and/or 50% (Stretch Goal ≤ $125,625 per month). The team used a five-day Kaizen Event (March 20-24, 2023) with an A3 Problem Solving Approach framework. Post Go-LIVE findings (May-December 2023) indicate a $160,087 monthly AVG and below our target. Our Kaizen has been an effective and efficient approach for Subject Matter Experts to share best practices and develop ideal Standard Work Instructions, which includes Overall Expiration Waste Reduction, Instant Adds, Inventory PAR Adjustments, and Inventory PAR Removal Processes. The team learned how to effectively use A3 problem solving and apply Lean tools to promote value-added activities. OR Inventory Coordinators execute their ideal processes with operational focus to prevent and reduce expiration waste. Engagement and ongoing success of this initiative requires buy-in from all levels of stakeholders (Executives, Surgeons, Directors, Managers, Inventory Coordinators from OR and Supply Chain, and Clinical Staff). Routine meetings and data transparency promote sustainment. The team expanded standard processes from ORs to all Procedural Areas (ORs, Interventional Radiology, Endoscopy, Cath Labs) and have prevented $5.2 million dollars (January - December 2023) out of $8.8 million in forecasted waste to close out 2023.