Saving Energy by Optimizing Warehouse Dock Door Allocation

As energy consumption constantly gains importance, it has become one of the major issues in managing logistics systems. However, it is ranked against other company priorities, and the rationalization for investing in energy needs to be justified by the savings achieved. A solution for reducing energy consumption via electric forklifts for performing docking operations at distribution centers, which requires no investments in infrastructure or equipment, is outlined in this paper. The solution is based on optimizing inbound dock door allocation, and the energy savings are quantified using a simulation model. A case study of a local FMCG distributor’s logistics center was conducted to collect the data and information needed for modeling inbound docking operations and performing simulation experiments. The optimal dock door allocation was obtained using a linear programming method using an MS Excel spreadsheet optimizer (Solver), while the simulation of the docking operations was carried out using FlexSim simulation software. The experimental results show that the solution outlined in this paper enables savings in the electric energy consumption of forklifts of between 12.8% and 14.5%, compared to the empirical solution applied by the company in the case study. The intended contribution of this paper is not limited to presenting an applicable solution for energy savings in performing logistics processes, but also aims to draw the attention of more researchers and companies to the ways in which logistics processes are managed and performed in terms of raising energy efficiency