NPI, DFM/DFA & Engineering Change worked example

PPAP Workload at 5.76% ppap workload utilization target: a worked example

This worked example runs the ppap workload numbers for a tougher week than the baseline: 5.76% ppap workload utilization target instead of the typical 8%. Estimate ppap workload for npi, dfm/dfa and engineering change using production-ready inputs so teams can compare demand with available capacity and identify overload risk.

The inputs for this scenario

  • Ppap workload demand: 100 units (held at the documented default)
  • Ppap workload capacity: 1.2 units (held at the documented default)
  • Ppap workload utilization target: 5.76 % (the input this scenario stresses; the baseline uses 8)

Working through the calculation

  • The calculation starts from the formula this tool documents: Required ppap workload load = ppap workload demand รท ppap workload utilization target.
  • Total load works out to 120 hr at these inputs, and this is the headline figure for the scenario.
  • Hourly equivalent works out to 20.83 hr / hr at these inputs.
  • Input load works out to 100 hr at these inputs.
  • Load factor works out to 1.2 x at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where ppap workload utilization target sits at 8% and the headline result is 120 hr, this scenario lands almost exactly on the baseline at 120 hr.
  • Use it during launch planning or supplier ramp when the PPAP queue is filling faster than your quality team can clear submissions. 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

  • Total load: 120 hr (headline result)
  • Hourly equivalent: 20.83 hr / hr
  • Input load: 100 hr
  • Load factor: 1.2 x

Run it with your numbers

  • To rerun this with your own numbers, open the live PPAP Workload calculator, set ppap workload utilization target to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.