Study of Sustainable Rail Wagon Unloading in a Real-Life Scenario Based on a Multi-Criteria Decision Framework Under Industry 5.0 Principles

This study aims to improve wagon unloading processes in a real industrial context characterized by operational variability, process constraints, and strict performance requirements. Traditional decision-making approaches in such contexts often rely on single performance indicators, which may lead to suboptimal and less sustainable decisions. In line with Industry 5.0 principles, which emphasize human-centricity, resilience, and sustainability, this paper proposes a multi-criteria decision framework to support more balanced and adaptive operational decisions. A real-world case study based on anonymized industrial data is used to evaluate different arrival-track operational configurations. The proposed model considers several indicators, including unloading time, throughput, tonnage, process variability, operational losses, and a proxy of operator exposure. To strengthen the human-centric dimension, an Operational Handling Exposure Proxy (OHEP) was introduced to capture manoeuvre-related operator exposure during wagon handling and batch repositioning. A weighted scoring system was then used to identify the most balanced configuration by considering trade-offs between performance, stability, losses and operator exposure. The results show that the arrival-track operational configuration influences loss structure, process stability and overall decision ranking more than direct throughput alone. Track 2 provides the best overall trade-off under the baseline MCDM weighting scheme, while Track 3 may become preferable when wagon-loss minimization is prioritized. The findings highlight the importance of integrating variability and human-centered indicators into industrial decision-making processes. In future work, the proposed framework could be extended using data-driven methods and machine learning to support predictive and adaptive optimization in Industry 5.0 environments. This study contributes to the literature by integrating real-world industrial analysis, multi-criteria decision-making, and sustainability-oriented optimization into a single decision support framework.