ERP & MRP Planning worked example

Capacity Gap Analysis with available capacity hours of 10,500 hr: a worked example in erp & mrp planning

What does the result look like when available capacity hours reaches 10,500 hr? The full calculation is worked below with real intermediate numbers. a capacity planner needs to quantify overload or unused capacity

The inputs for this scenario

  • Available capacity hours: 10,500 hr (raised for this scenario; the documented default is 4,200)
  • Required demand load hours: 4,650 hr (unchanged)
  • Reference capacity basis: 4,650 hr (unchanged)

Working through the calculation

  • Applying the documented formula (Capacity gap = available capacity hours - required demand load hours) to the inputs above produces each figure below.
  • At this operating point the engine returns 126 % for capacity gap percent, the number this scenario is built around.
  • At this operating point the engine returns 5,850 hr for capacity gap hours.
  • At this operating point the engine returns 10,500 hr for available capacity hours.
  • At this operating point the engine returns 4,650 hr for required demand load hours.

How this compares with the baseline

  • Against the tool's baseline example, where available capacity hours sits at 4,200 hr and the headline result is -9.68 %, this scenario comes in 1,400% above the baseline at 126 %.
  • A figure at this level is achievable when available capacity hours is genuinely sustained, not just peaked for a shift. It is a single-period, single-resource snapshot; a positive net gap can still hide a daily or work-center bottleneck that the aggregate number averages away.

Results at a glance

  • Capacity gap percent: 126 % (headline result)
  • Capacity gap hours: 5,850 hr
  • Available capacity hours: 10,500 hr
  • Required demand load hours: 4,650 hr

Run it with your numbers

  • Every input above is editable in the live Capacity Gap Analysis calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.