Configure-to-Order & Product Configuration worked example

Option Mix Workload at 13% option mix review and rework allowance: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop option mix review and rework allowance to 13%, then walk the calculation through step by step. Estimate labor hours required to process option-heavy configure-to-order demand.

The inputs for this scenario

  • Option lines to review or process: 640 option lines (held at the documented default)
  • Option processing pace: 85 option lines / hr (held at the documented default)
  • Option mix review and rework allowance: 13 % (the input this scenario stresses; the baseline uses 18)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base option mix workload = option lines to review or process รท option processing pace.
  • estimated option mix workload works out to 8.51 hr at these inputs, and this is the headline figure for the scenario.
  • base option mix workload works out to 7.53 hr at these inputs.
  • option mix review and rework allowance works out to 13 % at these inputs.
  • option processing pace works out to 85 option lines / hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where option mix review and rework allowance sits at 18% and the headline result is 8.88 hr, this scenario comes in 4.24% below the baseline at 8.51 hr.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to option mix review and rework allowance, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. A single average processing pace hides the fact that some option lines (custom logic, engineered-to-order substitutions) take far longer than catalog selections, so heavily skewed mixes will be under- or over-estimated.

Results at a glance

  • estimated option mix workload: 8.51 hr (headline result)
  • base option mix workload: 7.53 hr
  • option mix review and rework allowance: 13 %
  • option processing pace: 85 option lines / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Option Mix Workload calculator, set option mix review and rework allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.