Doors, Hardware & Access Control Manufacturing worked example

Custom Order Lead Time with daily custom opening or hardware demand of 3,000 openings or sets / day: a worked example in doors, hardware & access control manufacturing

What does the result look like when daily custom opening or hardware demand reaches 3,000 openings or sets / day? The full calculation is worked below with real intermediate numbers. Use it when custom order lead time in doors, hardware and access control manufacturing is being sized for a buffer or safety stock review.

The inputs for this scenario

  • Daily custom opening or hardware demand: 3,000 openings or sets / day (raised for this scenario; the documented default is 1,200)
  • Custom order replenishment lead time: 85 days (unchanged)
  • Schedule-change safety buffer: 1.1 openings or sets (unchanged)

Working through the calculation

  • Applying the documented formula (Lead-time demand coverage = daily custom opening or hardware demand × custom order replenishment lead time) to the inputs above produces each figure below.
  • At this operating point the engine returns 32.09 openings or sets for protected days of supply, the number this scenario is built around.
  • At this operating point the engine returns 35.29 days for unprotected days.
  • At this operating point the engine returns 3,000 pieces for inventory.
  • At this operating point the engine returns 85 pieces / day for daily usage.

How this compares with the baseline

  • Against the tool's baseline example, where daily custom opening or hardware demand sits at 1,200 openings or sets / day and the headline result is 12.83 openings or sets, this scenario comes in 150% above the baseline at 32.09 openings or sets.
  • A figure at this level is achievable when daily custom opening or hardware demand is genuinely sustained, not just peaked for a shift. It assumes steady daily demand; custom door work is lumpy by nature, so a single large opening release can consume coverage far faster than the average day implies.

Results at a glance

  • Protected days of supply: 32.09 openings or sets (headline result)
  • Unprotected days: 35.29 days
  • Inventory: 3,000 pieces
  • Daily usage: 85 pieces / day

Run it with your numbers

  • Every input above is editable in the live Custom Order Lead Time calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.