An Integrated Lean-Visual-Green (LVG) Model for Warehouse Layout Optimization and Carbon Footprint Reduction: A Case Study in the Food Products Industry
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Abstract
In modern industrial logistics, managing warehouses presents a key challenge-enhancing operational efficiency while minimizing environmental impact. However, existing studies on lean and green warehouse practices often address these dimensions separately, with limited integration into a unified framework applicable in real industrial contexts. This study proposes an integrated Lean–Visual–Green (LVG) model that combines waste reduction, visual control, and environmental impact assessment into a single analytical approach. Unlike conventional lean–green models, the LVG framework incorporates visual management to enhance operational clarity and support layout decision-making. A before–after comparative design was applied in a finished-goods warehouse in the food products industry with 81 stock-keeping units (SKUs). One year of historical data was analyzed to develop a Product Utilization Index (PUI), which was used for ABC classification and warehouse layout redesign. Following implementation, forklift travel distance decreased from 3,519,647.28 to 1,385,685.20 meters per year (-60.63%), with a corresponding reduction in CO2 emissions from 35,372.49 to 13,926.11 kgCO2 per year. The results demonstrated that the LVG model provides a practical and integrative approach for improving warehouse efficiency and reducing environmental impact through data-driven layout optimization.
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