systems thinking and lean transformation · standard work september 16‐20 ... – handling...
TRANSCRIPT
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A Transformational Gift . . .
It is the duty of everyone to do
what is within his power to
alleviate human suffering.
One NemoursAn Integrated System Of Care . . .
• 2 Hospitals• 12 Partner Hospitals• 37 Outpatient
Practices• 6 Urgent Care Centers• 679 Physicians• 215 Researchers• 114 Residents,
Fellows and Students• 6,427 Associates
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We here today…..• Why the traditional industrial model was inadequate for a pediatric surgical setting
• What was needed to move us forward• How we accomplished the transformation• Our current state and outcomes• Story of our 3‐year lean transformation journey
– Patient safety and patient flow– Pre‐Op through Discharge from PACU– Support Services (EX: SPD, EVS, OR Pharmacy)
Learning Objectives• Understand the components of the Integrated Lean Systems Model and the implementation challenges
• Understand the impact of high‐performance, multidiscipline teams on the ability to sustain improvements in quality, safety, delivery and cost
• Learn the importance of visible senior leadership, a daily management system, and the P‐D‐C‐A problem solving methods to lean transformation
Patient and Family Dissatisfaction
• What we heard from our patients in 2011– “we don’t want to come in several visits prior to surgery; why can’t we do everything the morning of surgery”
– “we don’t want to wait”– “we want to be better informed about delays” – “we want to know our surgery information sooner”– “please listen to our concerns postoperatively
• Variations in how patients flowed through our system (PAT > POH > OR > PACU)
• Scheduled $400,000 expansion plan to add 5 Pre‐Op Holding bays
• State of healthcare and changes
Why Continuous Improvement• Provide the optimal patient/family experience
– Best care and safety – Permanently reduce cost – Embrace patient/family variation and eliminate performance variation
• Improve our competitive position and brand recognition
• Become the “pediatric hospital of choice”
Using Traditional Event‐Based Model– Relentless pursuit of waste (non‐value added)– Patient flow as an analogy to assembly line flow – External facilitators, internal CI resources, VSM and Sponsors
– Emphasis on front line involvement with leadership support
– Managed through 30+ metrics and alignment sessions
– Maintained an aggressive redesign and implementation schedule
Event‐Based Model – Traditional Format
3‐Day Assessment and Planning
5‐Day Rapid Process Improvement Workshop
Following Week: Implement ChangesTrack Progress:
Confirmations, Data, Reports
Sustain: 30‐, 60‐, 90‐Day Reports to leadership
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Sponsors/MGT
Process Owners
Staff
VSMCI
Clinical Educators
Facilitator
Testing The Model – POH Patient Flow: Nov. 2011/Jan. 2012
• Patient registration through in OR – improved flow• Implemented late January 2012• Reduced process steps from 95 to 33• Reduced DOS mean wait time 128 minutes to 78 minutes by April 2013
• Stabilized the process for patients and staff • Waited until February 2013 for next POH event• Eliminated need for $400,000 capital project
Testing The Model – Administrative Function: July/August 2012
• OR Case Scheduling ‐ accuracy of case scheduling on first pass
• Implemented August 2012 • Increased entry accuracy General Surgery and Otolaryngology
• Failed to generalize to other services• Restarted in mid‐2013: failed to gain traction• Restarted in early 2014 (through integrated systems model)
2013 Event ScheduleMonth Date Event Type DescriptionJanuary 8‐9 Assessment & Planning PAT Screening
January 21‐25 RPI SPD Case Cart Picking
February 5‐7 Assessment & Planning Equipment Maintenance
February 12‐14 Assessment & Planning OR Set‐Up Wheels‐Out/WheelsIn
February 18‐22 RPI PAT Screening
April 9‐11 Assessment &Planning SPD Decontamination
April 15‐19 RPI Equipment Maintenance
April 25 Mini Alignment session
May 7‐9 Assessment & Planning PAT Standard Work Clinical
May 13‐17 RPI RPI OR Set‐Up Reduction
June 10‐14 RPI SPD Decontamination
July 9‐11 Assessment & Planning SPD Tray Assembly
July 15‐19 Study Trip
2013 Event Schedule (continued)Month Date Event Type Description
July 22‐26 RPI PAT Standard Work Non Clinical
August 6‐8 Assessment & Planning Daily Schedule Accuracy
August 13‐15 Assessment & Planning SPM Clean Up/ InstrumentVolume/ Maintenance
September 10‐12 Assessment & Planning PACU Phase 1/Phase 2 Flow and Standard Work
September 16‐20 RPI SPD Instrument Tray Assembly
October 7‐11 RPI Daily Schedule Accuracy
October 21 Alignment Session 2
OctoberNovember
28‐1 RPI SPM Clean/Up Instrument Volume/Maintenance
November 11‐15 RPI PACU Phase 1/Phase 2 Flow &Standard Work
December 3‐5 Assessment & Planning OR Preference Cards Standardization
December 17‐19 Assessment & Planning Pharmacy Delivery Accuracy
And Then…July 2013 We Called A Timeout• Event and change fatigue • Data indicated process changes were not stabilizing – variation
• Patient/family satisfaction feedback showed minimal improvement
The Turning Point: Team Study Trip
• Created contradictions– “Relentless pursuit of waste vs. “whatever it takes” – “Independent thinking and freedom to practice” vs. “reliable methods and standard work”
• Failed to adequately prepare staff – Absence of buy‐in among operating room staff – “we don’t make cars; patients don’t move along an assembly line”
– Lean concepts “foreign” to healthcare providers – Flow? Level Loading?
– Belief that lean transformation is “only about the money”
• Expected a “magical” change in perspective– Absence of a business perspective and failure to accept the financial state of the healthcare industry
– Approach process improvements from the customer’s perspective
– “Patients/families aren’t our customers…we provide care and safety”
Outcome? Non‐Adopters; Withdrawal; Obstruction
• Rigid redesign and implementation model– Only one tactic for every problem– Only focusing on waste reduction…failure to address gaps
• Continuously destabilized processes– Aggressive schedule had to be maintained
• Embracing teams and sub‐optimizing with silos• Taking a “shoulda’, oughta’, wanna’ approach to reliable methods and standard work– Trained and implemented without a performance management system
– Process destabilization rooted in performance variation
• Failing to manage on a daily basis– Casual daily oversight– Weekly MGT meetings– 30, 60, 90 day reports by Process Owners
• Functioning from a tactical rather than strategic vantage point– Tracking an array of discrete process metrics from isolated events
– Absence of cascading goals strategic metrics and cascading events
Outcome?Fragmentation, Whack‐a‐Mole, Collateral Damage
• Who:– Perioperative Services, Surgical Services, Anesthesiology, Sterile Processing, Environmental Services, Materials Management, Bio‐Med, Facilities, OR Pharmacy, Quality, Financial Services, Human Resources, Legal and Risk Management, Continuous Improvement
– Feeder Lines: Emergency Department, Inpatient Units, Intensive Care Units, Surgical Clinics
• What:– Enterprise‐wide guiding principles:
• eliminate contradictions; everyone on the same page– Education
• why we need to transform our processes• eliminate knowledge gaps
– Engagement and Empowerment:• authors/designers of “how”• equal membership; online andons and stoppage rights
– Leveraged Visible Leadership: • consistent messaging, firm expectations, guiding principles, patient/family experience, and our customer
Profile: High Performance Multidiscipline Team
• Collaborative relationship between all stakeholders– Partners beyond the operating room (POH, PACU, EVS, SPD)– Stakeholders outside Perioperative Services– Family Advisory Committee
• Sharing responsibility and accountability• Owning each others goals and success• Challenging and escalating as a value• Embracing the ultimate focus….”what is best for the patient”
• Enterprise True North Mission– Patient/Family Experience and Satisfaction– Quality, Safety, Delivery, Cost
• Moved from “I think to I Know”– Financials; business plan; competitive benchmarking– Operation metrics: Quality, Safety, Delivery– Voice of the customer, leadership and staff– Current state of the Value Stream
Cascading Enterprise True North to Strategic Initiatives
• Likelihood To Recommend – Top Box Goal• Surgical Site Infection – “0”• First Case Starts – 75% On Time• OR Case Turnover – Reduce Wheels Out to Wheels In Time
• Cost Per Case – Lap Appy and T & A
• Tiered daily huddles• Standard structure to maintain consistency
– DMS boards– Handling abnormalities (on‐line and off‐line)– Escalation system
• Cascaded metrics – Quality, Safety, Delivery, Cost
Cause Frequency Tracker Month of __August 2014Freq
uency (dates of o
ccurrence in each cell)
25
20
15
10
5
Causes of Issues
Note: Causes of Issues should be written across the bottom. As causes repeat, additional dates should be written above the cause to show ascending frequency
05
101520253035404550
1. Sup
plies m
issing/
listed on
PL
2. Sup
plies
missing/no
t listed
on
PL
3. Instrumen
t missing
or broken from
tray
4. Case Cart not
available on
time
5. Breech in sterility of
packaged
item
Operating Room Andons 2014
Jan‐14
Feb‐14
Mar‐14
Apr‐14
May‐14
Jun‐14
Jul‐14
Aug‐04
Sep‐14
Oct‐14
0
5
10
15
20
25
6. Non
‐sterile room
supp
lies m
issing
7. Sterile supp
lies
missing/exhausted
8. Sterile glove supp
lyexhausted
9. Sterile gown supp
lyexhausted
10. Position
ing aids
not a
vail
11. Shared eq
uipm
ent
not a
vail
Operating Room Andons 2014
Jan‐14
Feb‐14
Mar‐14
Apr‐14
May‐14
Jun‐14
Jul‐14
Aug‐14
Sep‐14
Oct‐14
0
5
10
15
20
25
12. N
o Surgeo
n in OR
hudd
le
13. EVS
respon
se <
requ
ested
14. Com
puter C
OW
issue
s in OR
15. Pharm
acy Issue in
OR
16. Con
sent Issue in
OR
17. Problem
w/ O
Rph
one
Operating Room Andons 2014
14‐Jan
Feb‐14
Mar‐14
Apr‐14
May‐14
Jun‐14
Jul‐14
Aug‐14
Sep‐14
Oct‐14
05
101520253035404550
18. Problem
w/ O
Rmon
itors or cam
eras
19. OR Nurse neede
d as
escort to
PAC
U
20. Procedu
re add
ed to
or changed
during
hudd
le
21. R
oom re
ady at or
before 0740 hu
ddle late
22. Issue
s cop
ied for
Anesthesia fo
llow‐up
23. Incorrect item
picked
for case cart
24. Pho
ne Hud
dle
Operating Room Andons 2014
14‐Jan
Feb‐14
Mar‐14
Apr‐14
May‐14
Jun‐14
Jul‐14
Aug‐14
Sep‐14
Oct‐14
OR Room
Service Coordinators
Charge RN
OR Assistant Nurse Managers OR Manager OR Model Line
Sponsors
Chief Nurse Exectutive
Medical DirectorAnesthesia Director
Chief Operating Officer
VP Chief Medical Officer
Cheif Exec DE Operations
Sandy Cheezum
Chris Harris
Janice Gannon
Lani Heyman
Charge RN
10 60
Janice Simmons
Margaret Souder
Sharon Udy‐Janczuk
Bob Redlinger (Nursing)
Al Dorsey (Anesthesia)
Kirk Reichard (Surgeon)
Jane Mericle
Tetsu “Butch” Uejima
(Anesthesia)
Stephen Dunn(Surgeon)
Will Mackenzie(Orthopedics)
Paul Kempinski
Brent King
Roy Proujansky
2
Other Andons
10
Patient Safety
2
10
5
20
30
90
60
180
• Tiered daily huddles• Standard structure to maintain consistency
– DMS boards– Handling abnormalities (on‐line and off‐line)– Escalation system
• Cascaded metrics – Quality, Safety, Delivery, Cost
• Gemba ….”Go to the workplace”– “Real time” observation and problem solving
• Visible Leadership– Gemba walks– Tri‐folds and confirmations (spot checks)– Just‐in‐time solutions
• Plan‐Do‐Check‐Act Cycle
WHO Checklist - OR Coordinator/Charge
COMPLETE TASK ACTIONS & FOLLOW-UPValidate Cir RN goes to bedside and
visualizes patient id band and confirms with Anesthesia
Validate Cir RN reads consent audiblyValidate Cir RN completes sign in
documentationValidate Time out is initiated by surgeon
Validate elements of the time out: -Correct Patient, Procedure to be
performed (laterality), Site marking, prophylactic antibiotic, fire safety, equip
settings, imaging, blood products, concerns, team intro
Validate Time out occurs prior to procedure start
Validate if everyone is participating and paying attention (no competing
conversation or movement is occuring)Validate Cir RN Completes time out
documentationValidate sign out occurs after critical events of the procedure are performed and before the attending surgeon leaves the ORValidate the following:- Proc performed, Wound Class, Specific Concerns, Concerns for disp/recovery, Equip problems, Specimen confValidate no competing conversations occur during sign out
Date:
P‐D‐C‐A and Practical Problem Solving
I think its they don’t care
Go to the evidence
Which inpatient units
Deep‐dive w/ cross‐
functional team
Direct causes: process design;conditions; equipment; methods; individual performance
Solutions
Tracking outcomes
Responding to the data
Performance Management Component
Expectations
Train
Observation & Feedback
Consistency
Confirmations & Refinements
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Performance Targets
ReliableMethods
Coaching
Alignment
Sustaining
Continuous Cycle
Effective Feedback• Immediately after completing the observation • Specific vs. general or ambiguous
– “You completed the counts” vs. “you did a good job counting”• Objective based on real‐time observation of actions/behaviors listed on the confirmation card
• Personal and Sincere to the observer and the staff member– “I noticed that you reviewed the preference card….”
• Positive/Maintain and Constructive/Redirect
Event‐Based Model – Traditional Format
3‐Day Assessment and Planning
5‐Day Rapid Process Improvement Workshop
Following Week: Implement ChangesTrack Progress:
Confirmations, Data, Reports
Sustain: 30‐, 60‐, 90‐Day Reports to leadership
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• Everything is linked in some way• A slight tweak “here” may cause a collision “there”…collateral damage
• Solving “my” problem may create a new problem….whack‐a‐mole
• Solution:– Have all stakeholders represented including patients/families
– Make strategic decisions on who to include (champions, adopters, SMEs)
– Never move forward with changes before confirming feasibility (cost, technology)
– Never move forward without confirming changes do not conflict with established policies, procedures and regulations….compliance check
– Always ask: “how might this change impact……..
• Goal: To improve the value delivered to patients and their families
• Equation: Value in health care is measured in terms of the patient outcomes achieved per dollar expended
• Outcomes:measured along several dimensions, including survival, ability to function, duration of care, discomfort and complications, and the sustainability of recovery
• Costs: all resources including clinical and admin personnel, drugs, supplies, devices, space and equipment during a patient’s full cycle of care for a specific medical condition
• Eliminate unnecessary processes and process variations that don’t add value
• Improve resource capacity utilization• Deliver the right processes at the right locations• Optimize over the full cycle of care• Capture the payoffs• Reexamine reimbursement• Be better leveraged when engaging with managed care companies
Outcomes
• Process Improvements• Financial Savings• Patient and Family Experience/Satisfaction• Beyond The Process Metrics
Process Improvements
• OR Room Turnover (Wheels Out to Wheels In)• OR Room Utilization• First Case Starts• SPD Decontamination, Tray Assembly and Case Cart Picking
• Patient Flow – In Surgical Services through In O.R.
• Patient flow through POH– On‐time arrival, registration, POH check‐in, H & P, labs/x‐rays, site marking, consents, pre‐meds
• Environmental Services– Case cart removed and delivered to dirty lift; call SPD– Trash removed and room cleaned
• Sterile Processing– Correct case carts staged in core 1 hour prior to case start time
• OR room ready– Opening, inspecting/flushing and staging instrumentation– Receiving handoff– Room ready 5 minutes prior to scheduled start time
• Surgical team ready– Team huddle completed 10 minutes prior to scheduled First Case Start
• Anesthesia pulling patient to OR• Case scheduling accuracy
For 7:45 start• POH check‐in complete within 15 minutes of arrival• Site marking, consents and pre‐med by 7:30• In‐room huddle completed by 7:35• Handoff completed by 7:40• Room ready light turned green by 7:40• Patient in the OR by 7:45
For 9:00 Start• POH check‐in complete within 15 minutes of arrival• Site marking, consents and pre‐med by 8:45• In‐room huddle completed by 8:50• Handoff completed by 8:55• Room ready light turned green by 8:55• Patient in the OR by 9:00
0
10
20
30
40
50
60
70
80
Average Minutes
Turnover By Service
October 2014
November 2014
December 201421
40
22
32
16
32
252327
Environmental Services Turnover
0.0
2.0
4.0
6.0
8.0
10.0
12.0
ORTHO GENERAL ENT EYES UROLOGY NEURO PLASTIC DENTAL CARDIO
11.1
8.2
5.6
10.0
8.2
0.0
8.8
8.0
0.0
Tracking and Problem Solving Room Ready
79
6/9/14 Monday
OR Provider
Set‐up Complete
On‐time/Late
Set‐up Complete (Includes Huddle)
Gap (min)
Patient out of POH
Gap (min)
Patient in OR
In OROn‐Time/
LateGap (min)
Procedure Start
Total Delay (min)
1 Reichard On‐time 7:31 AM 0:027:33 AM 0:02
7:35 AM On‐time 0:22
7:57 AM 0:26
2
3 Piatt Late 7:44 AM 0:057:49 AM 0:02
7:51 AM Late 0:32
8:23 AM 0:39
4 Nardone Late 7:45 AM 0:037:48 AM 0:03
7:51 AM Late 0:11
8:02 AM 0:17
5 Salvin On‐time 7:24 AM 0:147:38 AM 0:04
7:42 AM On‐time 0:06
7:48 AM 0:24
6 Powell Late 7:43 AM 0:047:47 AM 0:01
7:48 AM On‐time 0:07
7:55 AM 0:12
7 BaniHani On‐time 7:37 AM 0:187:55 AM 0:02
7:57 AM Late 0:31
8:28 AM 0:51
8 Bowen On‐time 7:34 AM 0:067:40 AM 0:03
7:43 AM On‐time 0:18
8:01 AM 0:27
9 Mackenzie On‐time 8:44 AM 0:349:18 AM 0:04
9:22 AM Late 1:18
10:40 AM 1:56
10 Gabos Late 7:45 AM 0:057:50 AM 0:01
7:51 AM Late 1:20
9:11 AM 1:26
11 O'Reilly On‐time 7:20 AM 0:237:43 AM 0:01
7:44 AM On‐time 0:06
7:50 AM 0:30
SPR 1 U. Shah On‐time 7:34 AM 0:097:43 AM 0:00
7:43 AM On‐time 0:05
7:48 AM 0:14
SPR 2 0:00 0:00 0:00 0:00
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%1‐De
c2‐De
c3‐De
c4‐De
c5‐De
c8‐De
c9‐De
c10
‐Dec
11‐Dec
12‐Dec
15‐Dec
16‐Dec
17‐Dec
18‐Dec
19‐Dec
22‐Dec
23‐Dec
24‐Dec
26‐Dec
29‐Dec
30‐Dec
31‐Dec
2‐Jan
5‐Jan
6‐Jan
7‐Jan
8‐Jan
9‐Jan
12‐Jan
13‐Jan
14‐Jan
15‐Jan
16‐Jan
19‐ Jan
20‐Jan
21‐Jan
22‐Jan
23‐Jan
26‐Jan
27‐Jan
28‐Jan
29‐Jan
30‐Jan
Utilization
Room Utilization ‐ Combined Graph
Goal
Actual DOS Summary
Projected Daily
Baseline
0%5%10%15%20%25%30%35%40%
Associate
Readiness =
46
Patie
ntRe
adiness =
29
Equip/Ro
omRe
ady = 24
Metho
ds = 24
Capacity = 5
Reasons for First Case Delays by Categories 11/7/14 through 12/18/14
0%10%20%30%40%50%60%70%80%90%100%
0
5
10
15
20
25
Late First Case Starts Delay Reasons: 11/7/14 through 12/18/14 (301 Cases; 128 Late)
Associate Readiness 11/7/14 through 12/18/14: 128 Late Cases; 46 Associate Readiness = 36%
Surgeon late to POH
Anesthesiologist late to POH
Consent issues
Surgeon Late to Huddle
Procedure add/change in POH
POH Check‐In Late
Surgeon Late to Huddle 11/7/14 through 12/18/14:
13 Surgeon Late = 10%
Physician Late to POH 11/7/14 through 12/18/14: 128 Late
Cases; 20 Physician Late = 16%
Patient Readiness 11/7/14 through 12/18/14: 128 Late Cases; 29 Patient Readiness = 27%
Inpatient sent for late
Inpatient late into POH
Outpatient late into POH
Labs, Xrays needed
Insurance Issue
0.00%
0.20%
0.40%
0.60%
0.80%
1.00%
1.20%
0
1000
2000
3000
4000
5000
6000
7000
8000
Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec.
Tray Volum
e
2012 2013 2014 Error Rate 2014 Error Rate Target = 0.79% 2014 YTD Error Rate = .71%
Sterile Processing Tray VolumeAnd Error Rate
• DOS Case Cancellation Rate– Reduced from 6.0% in 2012 to 2.8% YTD 2014
• POH Patient Preparation – Patient arrival time decreased from 90 to 120 minutes in 2011 to 45 to 60 minutes in 2014
– Total time POH preparation reduced from a median of 101 minutes in 2011 to 88 minutes YTD 2014 for a 13% reduction
– In Surgical Services to In POH (patient registration) reduced from a median of 54 minutes in 2011 to 20 minutes YTD 2014 for a 63% reduction
– In POH to In OR increased from a median of 47 minutes in 2011 to 61 minutes YTD 2014 for a 30% increase
• Total financial gains to date– $1.7 million savings in labor and materials
• Total of 6.5 FTEs eliminated from Perioperative Services in 2014 and 2.5 FTEs in 2015.
– $400,000 capital expenditure
– Reduction in cost per case• Lap Appy decreased from $1355 in 2011 to $672 YTD 2014 for a 50% reduction
• PAT Clinical Workflow – Process redesign yielded an FTE reduction in 2014– DOS H & Ps increased from 34% 2013 to 88% YTD 2014
– The most medically complex patients became the focus of the clinic
– Feedback from patients and families is consistently high praise for the change
• Position Reallocation– In 2015 2.5 vacant FTEs were reallocated to other departments
• Nemours’ Continuous Improvement HR Policy– Guarantees all staff displaced by position reductions will not lose their employment
• RNs and other associates had the option to interview for open positions– These staff members were given “first consideration” – RN’s transferred to employee Health and outpatient clinics closer to home
• Vacant positions were re‐allocated to support– Materials Management, ECMO, Physician Practices, Lactation Education, and Kids Health Program
– The role of Perioperative Services Improvement Specialist
• Process Improvements– Eliminated 6 handoffs during the PAT – POH – OR Flow– Increased Sage Cloth compliance – Decreased instrument processing errors– Created reliable methods to performance variation– Enhanced instrument inspection and flushing in the OR– Reduced instances of flash sterilization
• Process Improvements– Implemented screening of all surgical patients by Advanced Practice Nurse 2 weeks prior to surgery
– Created no‐reply information and education email sent to surgical patients 3 days prior to surgery
– Moved information/education call to all patients 2 days prior to DOS
• On‐Line Andons, Staff Engagement and Empowerment
• Initial flow mapping included parents • Family Advisory Committee involved with CI events• PACU postoperative calls:
– 99% satisfaction; 98% connect rate
101
Ambulatory SurgeryNemours/duPont Hosp. for Children
Question - Likelihood of recommending center
Going Beyond the Metrics• Education for patients/families 48 hour call, emails, on‐line video, DOS booklet
• Enhanced teamwork RN and APN In POH• Staff cross‐trained to work in PACU and SPRs• PACU staff pull patients from inpatient units to POH• Decontamination beginning in the OR• Multidiscipline high performing teams are real• Coordinated care among all disciplines eliminating redundancies and decreasing rework
Continue To….
• Work our strategic plan focusing on 5 key metrics• Direct energy toward reducing performance variation• Pursue technology improvements and data access• Enhance our Daily Management System• Expand employee engagement and empowerment
Continue To….• Always ask:
– “What (not who) caused this to happen” – “How will this proposed change impact…”
• Always view: – “Patients and their families as our customers”
• Always lead with:– “What is best for the patient (not what is best for me)”