Use of Lean in the emergency department: a case series of 4 hospitals
Abstract
Study objective We describe the effects of Lean, a process improvement strategy pioneered by Toyota, on quality of care in 4 emergency departments (EDs).Methods Participants in 2 academic and 2 community EDs that instituted Lean as their single process improvement strategy made observations of their behavioral changes over time. They also measured the following metrics related to patient flow, service, and growth from before and after implementation: time from ED arrival to ED departure (length of stay), patient satisfaction, percentage of patients who left without being seen by a physician (2 EDs), the time from ordering to reading radiographs (1 ED), and changes in patient volume.Results One year post-Lean, length of stay was reduced in 3 of the EDs despite an increase in patient volume in all 4. Each observed an increase of patient satisfaction lagging behind by at least a year. The narratives indicate that the closer Lean implementation was to the original Toyota principles, the better the initial outcomes. The immediate results were also greater in the EDs in which the frontline workers were actively participating in the Lean-driven process changes. A factor that considerably affected the outcomes in the second and third year postimplementation was the level of continuous leadership commitment to Lean.Conclusion Lean principles adapted to the local culture of care delivery can lead to behavioral changes and sustainable improvements in quality of care metrics in the ED. These improvements are not universal and are affected by leadership and frontline workforce engagement.
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Lean implementation in reviewed emergency departments was associated with decreased proportion of patients leaving the emergency department without being seen.
“Decreased proportion of patients leaving ED without being seen [ 72 ] [ 75 ] [ 76 ] [ 77 ] [ 81 ] [ 83 ]”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
Not every study adequately reported pre- and post metrics; in some cases measures of success were taken but not reported, patient satisfaction was not described, statistical tests were not used, or no numerical data were given.
“Fourth, not every study adequately reported pre- and post metrics. In some cases, “measures of success” (e.g., door-to-balloon time, door-to-needle-time) were taken but not reported [69]. In others, measures such as patient satisfaction were not described [83], statistical tests were not used to test pre-post differences [20, 75], or no numerical data were given to support reported changes [83]”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
Lean implementation in reviewed emergency departments was associated with decreased emergency department length of stay.
“Decreased ED length of stay [ 72 ] [ 73 ] [ 75 ] [ 76 ] [ 79 ] [ 80 ] [ 81 ] [ 83 ] [ 85 ]”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
With one exception, all Lean initiatives involved frontline staff in some way.
“Project team composition varied among sites, but with one exception (Hospital C in [75]), all Lean involved frontline staff in some way.”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
Some reviewed studies reported that employees became empowered to control the design of their own work.
“some studies indeed reported that their employees became empowered to suggest future changes [72] and to control the design of their own work [75]”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
Only one reviewed study, Dickson et al., included multiple Lean implementations across multiple EDs and therefore only this study was able to directly address contingencies.
“Only one study, Dickson et a1 [75], included multiple Lean implementation across multiple EDs and therefore only this study was able to directly address contingencies.”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
Based on a comparison of four EDs, Dickson et al. proposed that the two key contextual contingencies were involvement of frontline staff in Lean initiatives and leadership commitment to Lean.
“Based on a comparison of four EDs, Dickson et a1 proposed that the two key contextual contingencies were (a) the involvement of frontline staff in Lean initiatives, and (b) leadership commitment to Lean.”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
Lean implementation in reviewed emergency departments was associated with increased patient satisfaction.
“Increased patient satisfaction [ 73 ] [ 75 ] [ 81 ] [ 83 ] [ 85 ]”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
Dickson et al. proposed that Lean's variable success could be understood as "context + mechanism = outcome," where context refers to the local context of the ED and mechanism refers to Lean.
“more formally proposed that Lean’s variable success could be understood as “context +mechanism = outcome,” where context refers to the local context of the ED and mechanism refers to Lean [75].”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
In one reviewed study, there was decreased patient satisfaction.
“Decreased patient satisfaction [ 75 ]”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
There is a current trend of reporting bias toward publishing positive-and more often than not immediate-results because hospitals who failed to achieve intended behavioral changes do not come forward to openly analyze reasons for failure.
““there is a current trend of reporting bias toward publishing positive—and more often than not immediate—results because hospitals who failed to achieve the intended behavioral changes do not come forward to openly analyze the reasons for their failure” [75].”
From Lean Thinking in Emergency Departments: A Critical Review (2011) · cites this paper as [75]
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Lean Thinking in Emergency Departments: A Critical Review
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- Authors
- Dickson, E. W., Anguelov, Z., Vetterick, D., Eller, A., & Singh, S.
- Affiliations
- University of Massachusetts Chan Medical School (US)
- University of Iowa (US)
- Baylor St. Luke's Medical Center (US)
- University of Iowa Hospitals and Clinics (US)
- Corresponding author
- Dickson, Eric W.
- Anguelov, Zlatko
- Venue
- Annals of Emergency Medicine
- Publisher
- Elsevier BV
- Published
- 2009-10
- Volume
- 54
- Issue
- 4
- Pages
- 504-510
- ISSN
- 0196-0644 (ISSN-L)
- OpenAlex
- W2007318974
- Cited by
- 244
- References
- 24
- Citations by year
- 2026: 2 · 2025: 4 · 2024: 6 · 2023: 8 · 2022: 7 · 2021: 19 · 2020: 30 · 2019: 16 · 2018: 19 · 2017: 19 · 2016: 13 · 2015: 27 · 2014: 24 · 2013: 14 · 2012: 15
- FWCI
- 24.57
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- Annals of Emergency Medicine (publishedVersion)
- PubMed (publishedVersion)
- Topics
- Health Sciences › Health Professions › Health Information Management › Healthcare Quality and Management
- Health Sciences › Medicine › Emergency Medicine › Emergency and Acute Care Studies
- Health Sciences › Health Professions › Emergency Medical Services › Healthcare Operations and Scheduling Optimization
- Keywords
- lean healthcare, emergency department, process improvement, quality of care, length of hospital stay, patient satisfaction, patient flow, patient volume, leadership commitment
- MeSH terms
- Emergency Service, Hospital, Hospitals, Community, Hospitals, Teaching, Humans, Length of Stay, Management Quality Circles, Organizational Innovation, United States, Patient Satisfaction, Process Assessment, Health Care, Organizational Case Studies
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