Logistics Optimization in the SustainEra Mirafiori Hub: A Case Study on Presorting and Sorting Areas

Optimizing logistical workflows in the Pre-Sorting and Sorting areas of the SustainEra Mirafiori Hub is essential due to the wide variety of automotive components processed and the need for operational flexibility. In collaboration with the Centro Ricerche Fiat and framed within the principles of Industry 5.0, this study proposes innovative solutions to enhance performance in these critical areas of the plant. To address the complexity of managing a broad range of parts and components, two distinct models for optimizing the Pre-Sorting area have been developed, alongside an additional model aimed at improving the flows between Pre-Sorting and Sorting. These models integrate advanced automation technologies designed to streamline processes, optimize manual intervention, and improve overall productivity. The proposed models are rigorously analyzed, designed, and validated using Siemens Plant Simulation software, offering a detailed comparison with the existing system. This simulation-based validation ensures that the proposed solutions not only meet the operational demands of the Hub but also deliver significant improvements in speed, flexibility, and resource allocation. The design of these systems accounts for productivity challenges while ensuring scalability and adaptability to handle varying volumes of incoming products, providing essential flexibility for efficiently managing fluctuations in input. In addition to the technical evaluation, the study briefly explores potential marketing strategies, outlining how the optimized system could strengthen Stellantis' position within the sustainability-driven market.