ERP & MRP Planning calculator

Capacity Gap Analysis Calculator

Capacity Gap Analysis shows whether demand exceeds available capacity and how large the shortfall or surplus is.

What this calculator does

  • Calculate the gap between available capacity and required capacity, reported against a reference capacity basis.
  • a capacity planner needs to quantify overload or unused capacity
  • It calculates capacity surplus or shortfall for a work center, line, or period.

Formula used

  • Capacity gap = available capacity hours - required demand load hours
  • Capacity gap percent = capacity gap ÷ reference capacity basis × 100

Inputs explained

  • Available capacity hours: Use available machine or labor hours after planned downtime, shifts, and staffing limits.
  • Required demand load hours: Use routing load, MPS load, backlog load, or committed order hours.
  • Reference capacity basis: Use required load or available capacity as the denominator for the percentage gap.

How to use the result

  • Use it during ERP cleanup, MRP review, production scheduling, S&OP prep, purchasing decisions, shortage meetings, capacity planning, or daily shop-floor execution reviews.
  • This is a planning estimate. Confirm final commitments against current ERP/MRP records, released BOMs and routings, inventory accuracy, supplier commitments, open work orders, quality holds, and shop-floor constraints.

Common questions

  • What is the Capacity Gap Analysis calculator for? It calculates capacity surplus or shortfall for a work center, line, or period.
  • What information do I need before using it? You need available capacity hours, required load hours, and a reference basis.
  • How should I use the result? Use it to decide whether to add overtime, outsource, move demand, or change due dates.
  • When is the result only an estimate? It is only an estimate when demand, inventory, lead time, routing hours, setup time, yield, supplier dates, or work-center capacity comes from forecast assumptions or stale ERP data instead of current orders and recent execution history.

Last reviewed 2026-05-12.