Using simulation modelling to support decision-making in warehouse internal logistics

Abstract Manufacturing and logistics companies increasingly rely on warehouse automation and data-driven planning; however practical tools for evaluating how structural decisions influence outbound performance remain limited. This paper addresses this gap by developing a discrete-event simulation model of a warehouse system in which forklifts execute pallet transport tasks according to predefined shipment schedules. The model integrates real inventory data, structured storage addressing (alley-bay-level-slot), forklift routing logic and dock-capacity constraints within a unified ProcessFlow architecture. The experimental study focuses on assessing the impact of dock capacity on outbound operational performance. Three scenarios with varying numbers of docks were analysed while maintaining constant order structure, inventory distribution and transport logic. The evaluation is based on two key performance indicators: forklift utilization and average dock occupancy level. Statistical analysis was conducted using multiple replications and 95% confidence intervals to verify the significance of observed differences. The findings confirm that discrete-event simulation provides a robust decision-support tool for analysing structural modifications in warehouse systems and supports data-driven configuration of outbound logistics processes within Industry 4.0 environments.