Dr. Caprise, US: Enhancing OR efficiency and reducing costs through targeted tray optimization
At The Surgery Center of Lynchburg, Dr. Peter Caprise reduced hip replacement instrument trays from 8–9 to 5 per case, cutting sterile processing costs by $40,300 annually while streamlining workflows, easing staff workload, and improving sustainability.
At The Surgery Center of Lynchburg delivering high-quality, cost-effective care is central to their mission. The center had already partnered with DEO.care to leverage digital twin technology to improve workflow efficiency and increase OR throughput (read the case study here). When conversations turned to instrument use optimization, Dr. Peter Caprise and the team saw an opportunity to take the next step toward operational excellence.
Data-driven approach to kit reduction
Dr. Caprise, an experienced orthopedic surgeon, typically performs total hip replacements using the direct anterior approach. Before the project, each procedure required 8 or 9 instrument trays.
DEO.care used its Instrument Analyzer to capture real-world data from multiple procedures to analyze instrument usage. The analysis provided clear, data-driven insights into which instruments were always used, occasionally used and never used, indicating clear opportunities for improvement. Based on this, digital twin simulations were used to visualize various options for tray consolidation. (learn more about the process here)
Stakeholders across the center, including the Sterile Processing Department (SPD), reviewed the analysis together. With full alignment and buy-in, the team moved quickly to implement an optimized tray configuration. Within weeks, they had reduced the tray count by up to 4 trays, using just 5 per case.
Measurable gains
The results have been meaningful for the center:
Cost savings: The reduction in trays is projected to save the center up to $40,300 annually in sterile processing costs.
Workflow improvements: With fewer items to prepare, set up, and clean, procedures are more streamlined and efficient.
Sustainability gains: The decrease in tray count also means fewer sterilization cycles—reducing energy and water consumption.
Staff benefits: SPD and OR staff have less physical and mental strain due to fewer trays to transport, clean, and manage.
Looking ahead
The optimized tray configuration is now being trialed by other orthopedic surgeons at the center. If adopted across the board, the impact, both financial and operational, will grow exponentially. Dr. Caprise is also looking to extend this improvement to his hospital setting.
By acting quickly on the data and engaging the right stakeholders from the start, The Surgery Center of Lynchburg demonstrated a strong commitment to continuous improvement.
Their ability to move from insight to implementation in just a few weeks reflects a culture of collaboration and operational agility, laying the groundwork for even greater efficiencies in the future.