A Data-Driven Decision-Making Model for Configuring Surgical Trays Based on the Likelihood of Instrument Usages

In order to perform a surgical procedure, substantial numbers of sterile instruments should be readily available to surgeons through the containers referred to as surgical trays and peel packs. After the procedure, all instruments in the opened containers, regardless of whether they have been used or not, must go through the labor-intensive re-sterilization process. Empirical studies have shown that the utilization rate of instruments within trays is very low due to not having optimized tray configurations. Additionally, surgical trays often include instruments that are not likely to be used but are included “just in case”, which imposes an additional cost on hospitals through unnecessary instrument re-sterilization. This study is the first analytical attempt to address the issue of configuring surgical trays based on the likelihood of instrument usage through formulating and solving a probabilistic tray optimization problem (PTOP). The PTOP model can serve as a decision support for surgeons by providing them with the tray’s probability of being used for optimally configured trays and its associated reprocessing costs. The PTOP is constructed upon an integer non-linear programming model. A decomposition-based heuristic and metaheuristic method coupled with two novel local search algorithms are developed to solve the PTOP. The application of this model can be illustrated through a case study. We discuss how hospitals could benefit from our model in reducing the costs associated with opening trays unnecessarily before a procedure. Additionally, we conducted a risk analysis to estimate the level of confidence for the recommended solution.