Advanced Planning, Scheduling & APS worked example

Production Schedule Stability at 47% inside protected window: a worked example

This worked example runs the production schedule stability numbers for a tougher week than the baseline: 47% inside protected window instead of the typical 65%. Estimate schedule churn impact from changed orders, disruption cost per change, frozen-zone exposure, and replanning overhead.

The inputs for this scenario

  • Changed production orders: 26 orders (held at the documented default)
  • Disruption cost per change: 145 $ / change (held at the documented default)
  • Inside protected window: 47 % (the input this scenario stresses; the baseline uses 65)
  • Replanning and communication cost: 500 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Protected-window churn cost = changed orders × disruption cost per change × inside protected window.
  • Schedule churn impact works out to 2,272 $ churn impact at these inputs, and this is the headline figure for the scenario.
  • Disruption cost per change works out to 87.38 $ / change at these inputs.
  • Protected-window churn cost works out to 1,772 $ churn impact at these inputs.
  • Replanning and communication cost works out to 500 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where inside protected window sits at 65% and the headline result is 2,951 $ churn impact, this scenario comes in 23% below the baseline at 2,272 $ churn impact.
  • Use it to enforce a frozen-window policy, to quantify the cost of frequent reschedules, or in S&OP reviews where demand keeps churning the plan. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Schedule churn impact: 2,272 $ churn impact (headline result)
  • Disruption cost per change: 87.38 $ / change
  • Protected-window churn cost: 1,772 $ churn impact
  • Replanning and communication cost: 500 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Production Schedule Stability calculator, set inside protected window to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.