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Bar-Coded Surgical Sponges Reduce Error
Monday March 10, 2008

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To improve patient outcomes, Jo Quetsch, RN, MA, an operating room manager, and colleagues found a way to control sponge counts after surgery.

After implementing a new technology by SurgiCount Medical, Loyola University Health Center in Chicago became the first Midwestern facility to use a system that incorporates bar codes and scanners to keep track of surgical sponges.

The scanning process is similar to the technology modern grocery stores employ to scan grocery items, she says. The sponges are scanned at the beginning of a surgical procedure with a hand-held scanning device. At the end of a procedure, all the sponges are again scanned and accounted for.

Loyola's staff is not more likely to lose track of sponges during operative procedures than operating room staff at other institutions. However, keeping track of sponges can be problematic because more than 100 sponges can be used during a single operation, and some operations require more than 200 sponges at a time.

Also, several types and shapes of sponges are used during surgery, and the new device indicates what kind of sponge is missing, which is helpful, she says. If a sponge cannot be located, an X-ray is performed to ensure the wayward sponge was not left in the patient.

"Like any other organization, one [missing sponge] is one too many," Quetsch says.


The costs

Implementing the technology is expensive. It took about a month for staff to learn how to use the new technology and cost about $150,000 to put the system in place in the OR, labor and delivery department, and outpatient surgery department, Quetsch says. In addition, the health center uses about $60,000 worth of disposable sponges with the new technology per year.

But after only a few months with the new product — the system was implemented on Dec. 3 — the clinical director says it's worth the additional cost. "I would recommend it," Quetsch says. "I like the added assurance."

Inpatient manager Meg Kim, RN, BSN, CNOR, notes the financial output may seem hefty, however, "any retention of a foreign body can be very expensive" if there are complications or a lawsuit ensues.

"This is extra money upfront," Kim says. "But overall, it's cost effective."


Working out the kinks

The system was easy to implement, but glitches needed to be worked out, says Kim. At the beginning, individual sponges were scanned, which proved time-consuming. To reduce time, there is now a master tag for packages of five sponges that, when scanned, notes all the individual sponges in one bag. However, when the procedure is completed and the sponges are scanned again, they must be scanned individually, Kim says.

Kim says another problem detected early on was if a master tag was scanned in close proximity to an individual tag, the machine picked up only the individual sponge coding. Then, at the end of the procedure it would appear that there were missing sponges when there weren't any missing. Also, the technology will not allow a sponge to be scanned twice, Quetsch adds.

SurgiCount Medical was present 24/7 for the first two weeks that the system was in place, Kim says. Now they are on call by phone if there is a problem.


Saving time, reducing error

There are a lot of distractions in the OR and sponges easily can go missing, Quetsch says, so the new system reduces error.

However, to be sure there are no errors, OR staff continue to count sponges manually, she adds, as a double check.

Using the new technology also added about 10 minutes to each OR case time initially. "There has been a learning curve. I would say we're down to 5 minutes," Quetsch says.

"It's definitely a different work curve," Kim agrees. But it increases patient safety, she adds, so it's worth it.

Other institutions soon may decide to jump on the bandwagon and get the new device, too, Quetsch reports. According to recent studies, scannable surgical sponges will be the new best practice, she says.



Nancy Deutsch is a freelance writer. To comment, e-mail editorIL@nursingspectrum.com.

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