3yearplan/schemas/uns/portal-queries.md

UNS Hierarchy — Corporate AI Portal Queries

Purpose: factual lookup questions to send to the corporate documentation AI portal. These are distinct from QUESTIONS.md — that file holds design / convention questions for a human owner; this file holds factual questions whose answers exist in corporate documentation (site directories, ERP plant master, MES, asset register, plant-engineering docs, etc.).

How to use: fire each question at the portal independently. Paste the response under the question (in the Response block) as it comes back. Once a question is answered, fold the answer into the relevant subtree file (warsaw-west.json, warsaw-north.json, etc.) and/or into QUESTIONS.md if it resolves a design question.

Drafted: 2026-04-30. First answers folded in 2026-04-30 from OpenText Content Management CE 25.3 (livelink.nam.zimmer.com) browse session — the AI portal does not index OpenText, so this content was extracted via browser automation against folders we have access to (read-only, no downloads).

Source convention: answers tagged [OpenText: <breadcrumb>] cite the OpenText folder/document path; [AI portal] would be from the corporate AI portal (none yet).

Priority

• High — directly unblocks a per-site subtree file (Q1, Q2, Q3, Q6, Q7, Q9).
• Medium — shapes equipment-leaf walk and naming conventions (Q11–Q15).
• Low — confirms existing-standards alignment, low risk if unanswered (Q4, Q5, Q8, Q10, Q16–Q19).

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Site list & site codes

Q1 — Site list (High) — SUBSTANTIALLY ANSWERED

What is the authoritative list of manufacturing sites for the company, including which ones are active vs. planned vs. decommissioned, and which region each one belongs to?

Response (partial — corporate-entity folders, not necessarily all manufacturing sites): Top-level folders at [OpenText: Enterprise] representing Zimmer business units / sites:

• Zimmer Manufacturing B.V. (ZMBV) - Ponce
• Zimmer Shannon
• Zimmer TMT (Trabecular Metal Technology)
• Synvasive Reno
• Zimmer Austin Orthopedic
• Zimmer Beijing
• Zimmer Biomet Guaynabo (Puerto Rico)
• Zimmer CAS
• Zimmer Dental
• Zimmer Spine
• Zimmer Surgical
• Zimmer Trauma

Plus regional/grouping folders: Asia Pacific, Canada, Departments. The Warsaw, IN headquarters (with West Campus and North Campus) does not appear at this level — its content lives under Business Teams > Real Estate and Facilities > Warsaw Real Estate and Facilities. Galway is not visible at this level either — likely under Asia Pacific or another structure.

Caveat: these are content folders, not necessarily an authoritative manufacturing-site directory. A real site directory likely lives in HR / IT / ERP master data, not OpenText. The folder list here is best treated as a lower-bound of distinct business entities with documentation in OpenText.

Update (2026-04-30, post-download of Global Real Estate Information.xls, 580 KB, 2014 vintage = pre-Biomet-merger Zimmer-only data): master "Global Real Estate" worksheet has 198 rows covering 45 country sheets. Manufacturing-classified sites globally (filtered on Primary Use):

Country	City	Address	Sq Ft	Notes
Switzerland	Winterthur / Zurich	Sulzer Allee 8	251,339	Active major site — plan currently classifies as "not yet integrated"; needs reclassification
USA	Allendale, NJ	80 Commerce Drive	22,654	ZTMT Offices / Manufacturing — TMT is here
USA	Calabasas, CA	27030 Malibu Hills Rd	35,719	not in plan
USA	Carlsbad, CA	1900 Aston Avenue	44,757	not in plan
USA	Cedar Knolls, NJ	48 Horsehill Road	23,198	ZTMT Offices / Manufacturing
USA	Dover, OH	200 West Ohio Ave	138,000	not in plan
USA	Livingston, NJ	100 Navlon Ave	7,500	not in plan
USA	Mercedita, PR	Mercedita Plant	112,800	Separate from Ponce — PR has 2 sites
USA	Parsippany, NJ	10 Pomeroy Road	112,000	ZTMT Offices / Manufacturing — largest TMT site
USA	Ponce, PR	Parque Ind. El Tuque	12,054	matches plan's Ponce
USA	Statesville, NC	2021 Old Mountain Rd	80,001	not in plan
USA	Warsaw, IN	(9 addresses, 1,141,003 sq ft total)	—	see Warsaw breakdown below

Warsaw, IN — 9 manufacturing addresses (2014 legacy-Zimmer only; pre-Biomet-merger so does NOT include North Campus lettered buildings):

• 1800 West Center St — 552,230 sq ft (main HQ campus — the numbered buildings 2–20 are on this property)
• 508 Detroit Street — 24,820 sq ft (matches "Detroit St" PDFs in OpenText)
• 1610 W Armstrong Road — 30,764 sq ft
• 1612 Armstrong Road — 20,134 sq ft
• 1625 Armstrong Road — 16,378 sq ft
• 1639 Armstrong Road — 5,875 sq ft
• 320 Hepler Drive — 30,838 sq ft
• 400 S. Zimmer Rd — 19,000 sq ft

Several of these are likely the "Cessna" and "Detroit St" buildings that appeared in the OpenText Zimmer Biomet Buildings folder but didn't fit either the numbered or lettered scheme — they are auxiliary Warsaw, IN production buildings outside the main 1800 W Center St campus.

Notable absences from this 2014 doc: Shannon, Galway, Berlin, Jacksonville, and the lettered (Biomet) buildings — all of these are post-2015-merger acquisitions or sites that came in via Biomet.

Implication for UNS / plan: the plan's "Other integrated sites" list (Shannon, Galway, TMT, Ponce) is correct as the SCADA-integrated subset — most other sites in this list are not (yet) on the SCADA system. However, two corrections to the plan are warranted:

1. Winterthur, Switzerland is a major manufacturing site (251K sq ft active), not a "smaller footprint" not-yet-integrated site as current-state.md currently classifies it. Onboarding it via the standardized stack is a significantly larger effort than the plan currently implies.
2. TMT is in New Jersey (Allendale, Cedar Knolls, Parsippany) — three sites totaling 157K sq ft. The plan's tmt site shortname is fine but the location is NJ, not Indiana, not Japan (Japan is a separate registration). Mercedita, PR is separate from Ponce, PR.

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Q2 — Site code system (High)

Does the company use a standard site-code or facility-code system (for example a 2- or 3-letter code used across IT, ERP, HR, or finance)? If yes, what are the codes for Warsaw West, Warsaw North, Shannon, Galway, TMT, Ponce, South Bend, Berlin, Winterthur, and Jacksonville?

Response: (pending)

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Q3 — TMT meaning (High) — ANSWERED

What does the abbreviation TMT stand for as a manufacturing site, and what is its full official name? Where is it located?

Response: TMT = Zimmer Trabecular Metal Technology, Inc. — wholly owned subsidiary of Zimmer Holdings, Inc. Also does business as "Zimmer" and "Implex" (a/k/a "Zimmer Trabecular Metal Technology, Inc dba Zimmer and Implex"). Zimmer Biomet Canada is the contracted manufacturer for TMT-listed devices. Registered as a foreign medical-device manufacturer in Japan with establishment number BG30401579(TMT). Source: [OpenText: Enterprise > Zimmer TMT > ... > TMT ISO (SGS) Certificates / State of NJ... > SGS Reports > Past Reports] — the SGS audit reports 2023-10-03-AUR-SGSGU-F002993 SIGNED MDSAP... and 2021-09-27-AUR-SGSGU-F002993 SIGNED MDSAP.... Sub-finding: site has its own dedicated top-level folder Enterprise > Zimmer TMT with subfolders for Document Control (57 items), Quality, Sourcing — created by Virendra Atri in 2013, suggesting India-based ownership. Implication for UNS: the site shortname tmt aligns with the corporate naming; long-form display would be "Zimmer Trabecular Metal Technology" or "Zimmer TMT".

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Q4 — SAP plant codes (Low)

What are the SAP plant codes (or equivalent ERP plant identifiers) for each of our manufacturing sites?

Response: (pending)

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Q5 — Camstar MES site codes (Low)

What are the Camstar MES site codes in use, and how do they map to the physical sites?

Response: (pending)

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Warsaw campus building maps

Q6 — Warsaw West buildings (High) — ANSWERED

What is the authoritative list of buildings on the Warsaw West campus, including building number, building name, primary purpose (production / office / warehouse / lab / utility), and approximate footprint? Specifically, are buildings other than 5 and 19 used for production?

Response (partial): The Warsaw campus has far more buildings than just 5 and 19. Authoritative folder [OpenText: Enterprise > Business Teams > Real Estate and Facilities > Warsaw Real Estate and Facilities > Facility Information > Zimmer Biomet Buildings] (objId=4638251) contains 31 floor-plan PDFs, one per building/floor. Building inventory:

• Numbered buildings: 2 (1F), 3 (LL/1/2/3), 4 (1/2), 5 (1/2), 7, 8 (1/2), 10, 14 (1&2), 15 (Z Hotel — 4 floors), 17, 18, 19, 20.
• Lettered buildings: A (3 floors), B (2 floors), C, D, E, I (2 floors). Likely a separate sub-campus — they appeared together earlier under Asset_Management_Warsaw > BLDG A_009 > BLDG A CASE 6 SHELF 3_01 with a Mikron_Main Campus Map.pdf reference, suggesting these may be the Mikron facility / older building-letter naming convention.
• Named buildings: Cessna (1F & 2F), Detroit St-1 floor, Detroit St-2 floor (Detroit Street is in Warsaw, IN, so "Detroit St" buildings are Warsaw addresses, not Detroit).

West Campus / North Campus split is real (parent folder [OpenText: Real Estate and Facilities] has both North Campus Training and West Campus Training subfolders), but the building-to-campus assignment is not visible from folder names alone — it lives in the PDFs Zimmer West Campus.pdf (161 KB), Warsaw Facilities Location Map.pdf (117 KB), and the Excel Zimmer Warsaw - Building Use Descriptions.xlsx (12 KB) under Facility Information. Opening any of these requires an explicit download permission.

Authoritative facilities contact (2019): Vrushali Pandya, Sr. Facilities Specialist, Facilities Department, 1800 W. Center Street, Warsaw IN 46581 — Vrushali.Pandya@zimmerbiomet.com. Sourced from email [OpenText: 01-Zimmer Warsaw-Establishment No.-18225... > Establishment Registration > Map 3 mile radius > RE List and Map of West Campus Buildings.msg] (objId=56700739).

Implication for UNS: the original draft assumption of "Warsaw West = bldg-5 + bldg-19" is too narrow. Need either the West Campus PDF or the Building Use Descriptions Excel to finalize. Some "buildings" are office/hotel (Bldg 15 = "Z Hotel"), not production — purpose breakdown is critical before committing to UNS Areas.

Resolution (2026-04-30): project owner confirmed verbally that numbered buildings = legacy Zimmer = Warsaw West Campus, and lettered buildings (A, B, C, …) = legacy Biomet = Warsaw North Campus. This corresponds to the 2015 Zimmer-Biomet merger of two physically adjacent Warsaw, IN sites. The Building Use Descriptions doc (downloaded 2026-04-30) enumerates the numbered buildings 2–20 with use descriptions:

Bldg	Use
2	Printing Services, Bone Cement, Packaging Clean Rooms
5	Main manufacturing facility (Foundry, Mfg, Packaging, R&D, Quality, Engineering Services, …)
7	Tool Support Center, Upper Extremity Manufacturing
10	Hip and Knee Manufacturing, Packaging Clean Rooms
19	Trauma Corporate HQ + Trauma, Instrument, and Knee & Hip Manufacturing, Foundry
20	Scrap Salvage, Sheet Metal, Warehousing

Non-production: 3 (Executive offices), 4 (Distribution Center), 8 (Global Events), 14 (Airport Hangar), 15 (Z Hotel), 17 (IRS Offices), 18 (Residential Housing).

Resolution applied to warsaw-west.json: Warsaw West Areas = bldg-2, bldg-5, bldg-7, bldg-10, bldg-19, bldg-20 (production buildings only; non-production 3, 4, 8, 14, 15, 17, 18 excluded per the goal-state design that Areas at Warsaw campuses are production buildings).

Outstanding sub-questions (low priority, not blocking):

• Cessna and Detroit St-1 / Detroit St-2 PDFs were in the same Zimmer Biomet Buildings folder but are neither numbered nor lettered. They belong to neither West nor North under this rule. Likely separate auxiliary buildings or a third Warsaw facility — verify during the walk.
• Lettered building purposes are not yet known (no equivalent of the Building Use Descriptions doc was found for North Campus). All six lettered buildings are included in warsaw-north.json pending the walk; non-production ones should be removed once identified.
• Lettering jumps from E to I — verify whether F, G, H exist, were demolished, or follow a different naming.

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Q7 — Warsaw North buildings (High — primary blocker) — ANSWERED

What is the authoritative list of buildings on the Warsaw North campus, including building number, building name, primary purpose (production / office / warehouse / lab / utility), and approximate footprint?

Response: Lettered buildings (A, B, C, D, E, I) = Warsaw North Campus = legacy Biomet site. Confirmed verbally by project owner; corresponds to the 2015 Zimmer-Biomet merger of two physically adjacent Warsaw, IN sites. Six lettered buildings visible in [OpenText: Warsaw Real Estate and Facilities > Facility Information > Zimmer Biomet Buildings]: A (3 floors), B (2 floors), C (1 floor), D (1 floor), E (1 floor), I (2 floors). Lettering jumps from E to I — F, G, H not visible; verify during walk.

Resolution applied to warsaw-north.json: Warsaw North Areas = bldg-a, bldg-b, bldg-c, bldg-d, bldg-e, bldg-i — all included pending verification of which are production vs. non-production (no equivalent of the Building Use Descriptions doc was found for North Campus). Walk should remove non-production buildings.

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Q8 — Multi-floor production buildings (Low)

Are any Warsaw campus production buildings split across multiple floors with distinct production processes per floor? If so, which buildings and what's on each floor?

Response: (pending)

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Production lines & cells (per site)

Q9 — Production line inventory (High)

What are the named or numbered production lines currently operating at each integrated site (Warsaw West buildings 5 and 19, Warsaw North, Shannon, Galway, TMT, Ponce)? Looking for: line identifier, what the line produces, and where it physically sits within the site/building.

Response: (pending)

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Q10 — Existing plant taxonomy (Low)

Is there an existing plant taxonomy or work-center hierarchy documented anywhere — for example an ISA-95 model, a Camstar work-center tree, an Ignition project structure, or an Aveva System Platform Galaxy hierarchy — that already defines Site / Area / Line / Cell / Equipment for our sites?

Response: (pending)

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Q11 — Line naming convention in use today (Medium)

When a single physical production line is described across our internal documentation (engineering drawings, MES, capacity plans), is it named by a number (Line 1, Line 2), by a product or process (Assembly A, Packout, Injection 2), or by an internal code (e.g., MX-204)? Looking for the convention(s) actually in use today.

Response: (pending)

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Equipment naming & asset tags

Q12 — Asset-tag format (Medium)

What is the company's physical asset-tag format for production equipment (e.g., the printed/engraved tags on machines)? Looking for: the format pattern, what each segment means, and whether the format differs across sites or equipment classes.

Response: (pending)

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Q13 — Asset register / CMDB (Medium)

Is there a central asset register or CMDB that lists production equipment by site, including asset tag, manufacturer, model, and location (building / line)? What is it called and who owns it?

Response: (pending)

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Q14 — Existing System Platform / Ignition naming (Medium)

What naming convention is used for production equipment in Aveva System Platform (Galaxy object names) and Ignition (OPC UA tag paths) today? Are the conventions consistent across sites?

Response: (pending)

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Q15 — FANUC CNC count and locations (Medium)

How many FANUC CNC machines do we have, broken down by site and building? (The FANUC CNC class is the pilot for the new equipment-class template work, so a count by location would shape rollout sequencing.)

Response: (pending)

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Existing standards

Q16 — Existing UNS / ISA-95 standard (Low)

Does the company have an existing Unified Namespace (UNS), ISA-95 hierarchy, or manufacturing data model standard documented? If so, where is it published and who owns it?

Response: (pending)

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Q17 — Enterprise shortname zb confirmation (Low) — ANSWERED

Is there an existing enterprise-level shortname or stock-ticker-like abbreviation used in IT systems, document headers, or domain names that we should align our top-of-hierarchy zb segment with? (We're using zb today; want to confirm it matches an existing convention rather than introducing a new one.)

Response: Confirmed: zb aligns with Zimmer Biomet as the company name (the OpenText instance is at livelink.nam.zimmer.com; documents are signed off by @zimmerbiomet.com email addresses; the corporate signature uses "ZIMMER BIOMET" as the brand). NYSE ticker is ZBH but zb is a clean two-letter shortname that matches both the legacy "Zimmer" and the post-merger "Zimmer Biomet" brand. No change needed — keep zb as the top-of-hierarchy enterprise segment.

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Q18 — Non-production equipment classes (Low)

Is there a non-production equipment class list (compressors, chillers, HVAC, lab equipment) maintained at the corporate level, and which of these surfaces are typically connected to SCADA / monitoring at our manufacturing sites?

Response: (pending)

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Cross-site / shared resources

Q19 — Shared resources across sites (Low)

Are there any shared production or test resources (calibration labs, central inspection equipment, mobile test rigs) that are physically located at one site but logically serve multiple sites? If so, list them with their host site.

Response: (pending)

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Resolved

2026-04-30 — first pass against OpenText

• Q3 (TMT meaning) — fully answered. tmt site shortname stays; long-form name "Zimmer Trabecular Metal Technology" or "Zimmer TMT".
• Q17 (zb enterprise shortname) — confirmed. zb aligns with Zimmer Biomet brand; no change.
• Q1 (site list) — substantially answered. 2014 Zimmer global real-estate inventory shows 12 distinct manufacturing sites (legacy Zimmer only); plus Biomet-acquired sites (Shannon, Galway, etc.) added in 2015. Reclassifications applied to current-state.md: Winterthur is a major site (251K sq ft), not a "smaller footprint" site; TMT is in NJ (3 addresses); Mercedita is separate from Ponce.
• Q6 (Warsaw West buildings) — fully answered. Numbered buildings = legacy Zimmer = Warsaw West. warsaw-west.json updated with 6 production Areas: bldg-2, bldg-5, bldg-7, bldg-10, bldg-19, bldg-20.
• Q7 (Warsaw North buildings) — fully answered. Lettered buildings = legacy Biomet = Warsaw North. warsaw-north.json created with 6 Areas: bldg-a through bldg-e and bldg-i (purposes pending walk; non-production to be removed).

Open OpenText follow-ups

• Source a current-vintage manufacturing-site directory (the Real Estate workbook is 2014 and pre-Biomet-merger) — likely lives in SAP / HR, not OpenText.
• Optionally search OpenText for "Galway" and "Shannon" specifically since those Biomet-acquired sites are not in the 2014 real-estate workbook.
• The Global Site Pictures (21 items) folder is unexplored — could yield labeled campus photos useful for verifying the West/North split visually.