Case Study: Zimmer

System Summary

Zimmer is a worldwide leader in joint replacement solutions for knee pain and hip pain, and provides comprehensive spine care solutions for acute and chronic back pain. The company also provides a broad range of trauma, dental implant, and orthopaedic surgical products. Founded in 1927, Zimmer is committed to providing effective techniques in hip replacement and knee replacement for orthopaedic surgeons who restore mobility and relieve the pain of osteoarthritis and traumatic injuries. Our minimally invasive hip and minimally invasive knee replacement systems and our wide range of related products and services make us valuable partners to health-care providers in more than 80 countries.

Zimmer Distribution Center Illustration

Opened in 1991, this 87,000 square foot distribution center in Warsaw is fully automated for immediate turnaround of orders. Approximately 90 percent of orders received at this state-of-the-art facility can be shipped within 24 hours. A 44,000 square foot addition to this facility was opened in 2001. In 2005 a new addition of 165,550 square foot was opened. Giving the total square foot of 296,550.

Key Technology

  • Pick To Light (PTL)

Picking Technology

  • Twelve (12) pods of two high horizontal carousel pick modules (12’ high carousels with operator lift tables) – Operators pick an upper and then lower pick on each batch in the carousels
  • Two-level shelving-supported mezzanine where operator feed totes to both levels for static picking