ERP & MRP Planning worked example

Machine Plan Requirement with planned production units of 600 units: a worked example

This worked example runs the machine plan requirement numbers for a tougher week than the baseline: planned production units of 600 units instead of the typical 1,200 units. Estimate machine hours required from planned units, routing machine time, load factor, and setup multiplier.

The inputs for this scenario

  • Planned production units: 600 units (the input this scenario stresses; the baseline uses 1,200)
  • Standard machine hours per unit: 0.28 machine-hr / unit (held at the documented default)
  • Load or efficiency factor: 1.05 x (held at the documented default)
  • Setup and changeover multiplier: 1.18 x (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Machine requirement = planned production units × standard machine hours per unit × load factor × setup/changeover multiplier.
  • Required machine hours works out to 208 hr at these inputs, and this is the headline figure for the scenario.
  • Machine hours before setup multiplier works out to 176 machine-hr at these inputs.
  • Setup and changeover multiplier works out to 1.18 x at these inputs.
  • Planned units × standard machine hours works out to 168 machine-hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where planned production units sits at 1,200 units and the headline result is 416 hr, this scenario comes in 50% below the baseline at 208 hr.
  • Use it during rough-cut capacity planning or when validating a master production schedule against finite machine availability before releasing work orders. 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

  • Required machine hours: 208 hr (headline result)
  • Machine hours before setup multiplier: 176 machine-hr
  • Setup and changeover multiplier: 1.18 x
  • Planned units × standard machine hours: 168 machine-hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Machine Plan Requirement calculator, set planned production units to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.