Case Study: Zimmer achieves over 100% productivity gains with Bastian Solutions automated fulfillment

Zimmerman - Customer Case Study

Zimmer, a worldwide leader in joint replacement solutions, faced major order fulfillment challenges from rapid acquisition-driven growth, a proliferation of products, and strict requirements for lot control, product dating, returns, and reporting. To address these pressures, Zimmer partnered with Bastian Solutions to improve throughput and streamline fulfillment operations.

Bastian Solutions implemented an automated warehouse solution featuring 15 pods of two high horizontal carousels, pick-to-light, zero-pressure conveyor, ExactaWCS, ExactaWMS, and an HMI. The system transformed Zimmer’s 300,000-square-foot distribution center in Warsaw, Indiana, enabling immediate order turnaround, increasing picking productivity by over 100%, boosting returns putaway productivity by over 100%, and allowing about 90% of orders to ship the same day.

Zimmer