A least flexibility first heuristic to coordinate setups in a two- or three-stage supply chain

This paper is concerned with coordination aspects of supply chain management and, in particular, investigates setup coordination between two and three stages of a supply chain. The problem arises from a real application in the production chain of a kitchen furniture plant. In different stages of the plant, items are grouped according to different attributes. A setup is required in a stage when the new batch has a different level of attribute from the previous one. Two objectives are considered, i.e., minimizing the total number of setups and minimizing the maximum number of setups of the stages. The problem is to determine a sequence of batches in search for Pareto-optimal solutions with respect to the two objectives. Several metaheuristics, including genetic algorithm, simulated annealing, and iterated local search (ILS) have been proposed for the two-stage problem. In this paper, we develop a constructive heuristic, which combines a least flexibility first principle and a greedy search, for the two- and three-stage problems. Computational results show that the proposed heuristic performs significantly better than the genetic algorithm and simulated annealing. Although the proposed heuristic is inferior to the ILS, which employs two constructive initial solution heuristic, for the two-stage problem, it can be easily extended to the three-stage problem.