Hallmark Health

A multiphase renovation to expand storage capacity of Melrose-Wakefield Central Sterile Processing.


Melrose, MA

Project Size

6,100 SF

About this Project

Lean Design

This project utilized Lean planning practices.

A multiphase renovation to expand storage capacity of Central Sterile Processing, modernize the existing cart and utensil washers, provide new air handling unit dedicated to the CSP to maintain key pressure differentials between soiled and clean operations within the department.

The project benefited from a lean 3P and prototyping process that allowed the team to identify the smallest workable area for each step in the process allowing the team to maximize the area available for renovation in each phase of construction. It also identified the root cause of the through put issues which was originally thought to be the washers. It was determined that out of sequence work was the root cause for through put volumes and shortages in supplies, not the capacity of the equipment and cart washers. Shortages in utensils required washing cycles dedicated to address those shortages, holding up prep and pack for trays waiting for the clean utensils. This was addressed with a visual storage solution allowing staff to identify shortages quickly in the visual inventory wall. The lean work also streamlined the soiled washroom process providing both redundancy and new capacity to accommodate a growing surgical program, including equipment required for the new DaVinci robotics program.

The multiphase project extended between two 1970s buildings and was located in the basement level below diagnostic imaging. Cost was a key concern and the team evaluated multiple options including a temporary CSP trailer configuration before choosing the renovate in place option as the most cost effective for the client.