The challenge
In the Sulzer Group's international service business, the fast and precise supply of construction sites, maintenance projects, and service assignments plays a central role.
In the field of wastewater and industrial pumps in particular, spare parts often have to be delivered under time pressure and directly to changing locations—frequently with customer-specific labeling, individual label logic, and varying combinations of parts.
The challenge: Ensuring central spare parts availability while simultaneously labeling deliveries individually and simplifying service processes without additional logistics and administrative costs for customers.
Our services
Zilken took over operational and logistical spare parts management for the service organization of Sulzer Pumps – from picking and labeling to direct delivery to end customers.
- Definition of spare parts kits for each pump and service type (including seals, bearings, throttles, screw sets, etc.).
- Order-based picking of sets in Germany – including quality inspection, completeness check, and packaging according to Sulzer specifications.
- Integration of customer-specific labels and identifiers: Sulzer's own item numbers, barcodes, and packaging requirements.
- Direct shipping to end customer construction sites in the US and abroad – with consolidated shipping documents and electronic proof of delivery.
- Digital information flow to Sulzer: automated order confirmation, tracking information, and reporting on delivery performance.
The solution
Zilken acts as an extension of the Sulzer service team: spare parts are assembled in individual sets ready for installation, labeled, and delivered on time— ready for immediate use on site.
This significantly reduces handling and testing costs for Sulzer Service, shortens response times in emergencies, and increases reliability for end customers.
The clear label structure also ensures unambiguous traceability, uniform documentation, and less communication effort between service units.
Figures (benefits/KPIs)
Zilken took over operational and logistical spare parts management for the service organization of Sulzer Pumps – from picking and labeling to direct delivery to end customers.
- Definition of spare parts kits for each pump and service type (including seals, bearings, throttles, screw sets, etc.).
- Order-based picking of sets in Germany – including quality inspection, completeness check, and packaging according to Sulzer specifications.
- Integration of customer-specific labels and identifiers: Sulzer's own item numbers, barcodes, and packaging requirements.
- Direct shipping to end customer construction sites in the US and abroad – with consolidated shipping documents and electronic proof of delivery.
- Digital information flow to Sulzer: automated order confirmation, tracking information, and reporting on delivery performance.
Best practice – why this approach works
- Number of spare part sets: several hundred variants, depending on the pump type.
- Fehlerquote in der Kommissionierung: < 0,5 %.
- Time savings in the service process: 30 to 50% thanks to pre-assembled sets.
- Delivery reliability: > 98% on-time delivery.
- Administrative relief: no double processing of delivery notes or labels on the customer side.
Note: The key figures are based on recorded logistics data and empirical values from ongoing service projects with Sulzer pump organizations in Europe and overseas.
