Business Challenges

  • Tremendous volume growth through acquisition and a proliferation of products challenged Zimmer order fulfillment
  • Complexities consisted of strict lot control, product dating, returns, and reporting requirements

Automated solution increases productivity 100%

Zimmer is a worldwide leader in joint replacement solutions for knee pain and hip pain along with a variety of other medical products. Faced with a bloated product line and increasing demand, Zimmer saw an opportunity to optimize throughput with automated order fulfillment. They worked with the experts at Bastian Solutions to build a system that significantly increased productivity over their previous manual system.

Zimmer Pack Stations

Key Technologies



  • Zimmer’s 300,000 square foot distribution center in Warsaw, IN is fully automated for immediate turnaround of orders
  • Picking productivity increased over 100%
  • Approximately 90% of orders received at this state-of-the-art facility can be shipped same day.
  • Returns putaway productivity has increased by over 100%

Photos of our solution

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