Describe the challenge or problem you/your system experienced that motivated change or improvement. Please also identify the personnel, departments, any suppliers, distributors or GPOs involved in this process.
In January 2010, a collaborative team from nursing, procurement, information systems, and the IDN's CEO, used Lean Methodology to reduce wasteful time and motion required for nurses and other clinical staff to source and gather supplies for patient care.
Problems identified included:
- defects in inventory levels
- hoarding of supplies by nurses
- inaccurate inventory levels
- unnecessary rework
Using a Value Stream Analysis, the team demonstrated that Lost Revenues in the engaged department exceeded $4100/week. Spaghetti diagrams confirmed that nurses spend 8% of their time, walking on average, 10.1 miles/shift/unit, to find and gather supplies.
Characteristics of a "Desired State", which could be replicated in other nursing units, were defined; key factors included:
- leverage point-of-use technology for supply use
- employ standard locations and nomenclature for supplies
- limit touch points by consolidating supplies
- locate high volume supplies in ergonomic zones
- establish a clear standard of work for replenishment
Goals were set for 50% reductions in Lost Revenue and in time and motion spent by nurses finding and gathering supplies. Using "Gap Analysis", deficiencies between the "As Is" and "Desired State" were mapped. A "Solutions Approach" was developed; proposed solutions were validated and results measured.
By mid February 2010, the VSA team developed and implemented a "Completion Plan" that could be replicated throughout the IDN. Work was done to validate the achieved results, which included Lost Revenues savings of 79.2% and a greater than 50% reduction in time and distance required for nurses to source and gather supplies.
What was the initiative you implemented? When did you start the implementation process? How did those involved impact the desired results? Who was involved in the review process? Please identify by listing individual names and appropriate teams.
Beginning in 2005, Dale Locklair, VP of Procurement & Construction, began the initiative to reinvent McLeod's supply chain from a transactional, paper and sticker-driven department to an automated, service-focused department that could support the institution's mission and strategic vision.
In 2006, Carmen Winfield, Director of Procurement Services, advanced this work to free personnel from wasteful, burdensome work and enable them to focus on work that supported patient-centered care. With C-Suite support from Rob Colones, CEO, Fulton Ervin, CFO, and Marie Segars, Sr. VP and Hospital Administrator, a multi-disciplinary team consisting of supply chain, nursing, clinicians, information systems, and finance representatives worked collaboratively to leverage technology and automate the req-to-pay process, integrating point-of-use systems with MMIS, AP and Charge Master.
By 2010, savings from elimination of manual processes resulted in savings of over 20,200 hours/year. With no terminations, personnel were reassigned to bigger opportunities, as a part of McLeod's focus on continual improvement. Using Lean Methodology, these teams employed Rapid Improvement Events (RIE) to free nurses from time spent sourcing and gathering supplies to focus on providing safe, efficient, patient-centered care. Work has also resulted in reductions in Lost Revenues of over 30% and warehouse inventory by 39.8%, while increasing turns from an average of six/year to nineteen.
In 2011, the department's advanced use of the point-of-use technologies has resulted in a collaborative partnership with Omnicell and GHX to leverage their technologies to improve OR Bill-Only processes to reduce transactional costs and improve efficiencies for manufacturers and Providers.
Describe any challenges you encountered during the improvement process and how you overcame them.
Organizations are not machines that can be engineered and re-engineered. They are complex ecosystems organized around foundational values and rule sets (Whipple, 2009). How people interact with each other influences what emerges, both negatively and positively. We saw our institution, not as a conglomeration of systems or processes but as interconnected webs of living, evolving organisms (Lewin & Regine, 2000).
Recognizing the limits of our control as leaders, we focused on the development and nurturing of relationships as the best means for guiding our work. Our greatest challenge was to find ways in which our department could add value for patients. We chose to do this by seeking ways to align our work with the work that takes place every day in support of frontline caregivers, and not simply by managing to financial reports but through collaborative relationships that helped streamline the layers of work that occur within our institution, making incremental improvements that supported our institution's mission, vision and values.
By helping to improve organizational agility, alignment and adaptability in incremental steps, we have been able to sustain these small improvements through and across the institution, further leveraging each small step to achieve and sustain greater objectives.
What have been the tangible results thus far? Please provide estimates of future results. Please identify how you determined and measured your results.
As automation has replaced manual processes, caregivers have been afforded more time to focus on safe, efficient, patient-centered care. Since this work began in 2005, Lost Revenues were reduced by over 66%; PO exception rates declined from 51.3% to 3.76%. EDI transactions have reduced manual processes by 52.2%, and electronic payments have reduced labor requirements by 41.7%. Labor once required to manage bulk supplies on nursing floors has been reduced by 54% through the use of order scanning at PAR locations. Time once required by nurses to find and gather supplies for patient care has been reduced by 8% - the average nurse now has 3.2 more hours/week to provide patient care than before!
As trust for the department has grown among nurses and clinicians, responsibilities have grown. From serving only medical surgical locations in 2005, the department now manages supplies in the emergency room, operating room, specials, radiology and respiratory therapy.
Work, which began in late 2010 on managing operating room supplies, has progressed. Once all manual processes, the department is working with vendors to integrate surgical supply systems with physician preference cards, implant logs, charge master, and supply replenishment and to build algorithms that will help maintain more accurate physician cards.
A single scan of a product used will populate the implant log, reorder a product, create a purchase order and adjust the patient bill. The implications of this are a potential savings of over 7500 labor hours, a 17.5% reduction from what are now completely manual processes.