Reducing Wear Rate of Precision Surgical Instruments through Lean Six Sigma: A single-center retrospective study

BackgroundWith the continuous advancement of technology and rapid development of precision medicine, precision medical devices are increasingly being utilized in clinical diagnosis and treatment. These devices play a crucial role in clinical practice. However, improper use accelerates instrument wear and tear, increases hospital costs, and jeopardizes patient safety. In Mainland China, research on surgical instrument wear is limited. Healthcare institutions widely implement Lean Six Sigma (LSS) as a management tool to enhance medical quality and patient safety through process improvement. ObjectiveThis study aimed to reduce the wear rate of precision instruments using the LSS management method, thereby lowering medical costs and enhancing patient safety. It also seeks to provide recommendations to strengthen the quality management of hospitals. MethodsThe study applied five LSS phases (Define, Measure, Analyze, Improve, Control) to analyze instrument deterioration. The primary causes of instrument degradation were identified, and three major improvement plans were proposed: establishing an intelligent device traceability and sterile supply chain quality control management system, refining transportation management, and optimizing the instrument preprocessing position. This study compared the wear and tear rates of precision instruments before and after implementation of the LSS method from 2023 to 2024. ResultsThe wear rate decreased significantly from 17.63% to 6.54% (P<0.001), yielding direct cost savings of 769,000 Chinese Yuan (CNY),calculated from the reduced repair and replacement expenses. Furthermore, the satisfaction rates among surgeons and nurses rose from 83.33% to 95.83% and from 86.67% to 98.33%, respectively (P<0.05). ConclusionThe full lifecycle management of precision instruments based on LSS can effectively reduce the wear rate, lower hospital costs, and improve the satisfaction of surgeons and nurses in sterile supply departments. Data Access StatemenThe raw data used in this study are proprietary and cannot be shared publicly due to department confidentiality agreements.