Intelligent Control Approaches for Warehouse Performance Optimisation in Industry 4.0 Using Machine Learning

In conventional logistics optimization problems, an objective function describes the relationship between parameters. However, in many industrial practices, such a relationship is unknown, and only observational data is available. The objective of the research is to use machine learning-based regression models to uncover patterns in the warehousing dataset and use them to generate an accurate objective function. The models are not only suitable for prediction, but also for interpreting the effect of input variables. This data-driven approach is consistent with the automated, intelligent systems of Industry 4.0, while Industry 5.0 provides opportunities for sustainable, flexible, and collaborative development. In this research, machine learning (ML) models were tested on a fictional dataset using Automated Machine Learning (AutoML), through which Light Gradient Boosting Machine (LightGBM) was selected as the best method (R2 = 0.994). Feature Importance and Partial Dependence Plots revealed the key factors influencing storage performance and their functional relationships. Defining performance as a cost indicator allowed us to interpret optimization as cost minimization, demonstrating that ML-based methods can uncover hidden patterns and support efficiency improvements in warehousing. The proposed approach not only achieves outstanding predictive accuracy, but also transforms model outputs into actionable, interpretable insights for warehouse optimization. By combining automation, interpretability, and optimization, this research advances the practical realization of intelligent warehouse systems in the era of Industry 4.0.