Tray-based setups cut OR waste, setup time while boosting workflow satisfaction

Editor's Note

Introducing preassembled surgical trays sharply reduces OR waste and setup time while improving staff workflow satisfaction, Surgeries October 8 reports. The prospective study, conducted in a high-volume German urology center, compared tray-based setups with the “standard approach” for preparation across 64 procedures and found measurable ecological and operational benefits.

As detailed in the article, for endourological procedures, trays cut setup time by 35%, waste weight by 34%, and waste volume by 19%. For major open surgical procedures, setup time dropped by 43%, waste weight by 25%, and waste volume by 32%. Nurses rated workflow with trays exceptionally high, averaging 9.75 out of 10 for endourological and 8.9 for major open cases.

The study found that these standardized trays not only streamline OR preparation but also alleviate workload stress for perioperative nurses and surgical technologists. Staff described improved efficiency and fewer interruptions, reflecting both time savings and enhanced organization. Although daily case throughput did not increase, nursing teams reported reduced fatigue and better adherence to regular working hours, an important factor in staff retention. The article notes that while the trays were supplied at no cost for this study, future cost-effectiveness analyses should consider potential trade-offs between purchase price and savings from reduced waste, improved workflow, and higher staff satisfaction.

From an environmental perspective, the trays contributed significantly to reducing packaging waste in hospitals, which generate roughly 6 kilograms of waste per bed per day in Germany. The authors emphasized the ecological impact outweighs any modest disposal cost reductions. They also pointed to new opportunities for recycling if tray materials are transparently declared and designed using polyethylene or polypropylene components.