S&OP, Demand Planning & Forecasting worked example

Demand Review Workload at 7.2% setup, handling, and delay allowance: a worked example

Suppose setup, handling, and delay allowance falls to 7.2%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate demand review workload for sandop, demand planning and forecasting using production-ready inputs so teams can plan labor hours, schedule the work, or check whether the job fits the available shift time.

The inputs for this scenario

  • SKU-location forecasts to review: 120 units (held at the documented default)
  • Forecasts reviewed per minute: 12 units / min (held at the documented default)
  • Setup, handling, and delay allowance: 7.2 % (the input this scenario stresses; the baseline uses 10)

Working through the calculation

  • The calculation starts from the formula this tool documents: Base demand review workload time = demand review workload workload รท demand review workload completion rate.
  • Required demand review workload time works out to 10.72 hr at these inputs, and this is the headline figure for the scenario.
  • Base demand review workload time works out to 10 hr at these inputs.
  • Demand review workload allowance applied works out to 7.2 % at these inputs.
  • Demand review workload completion rate works out to 12 pieces / min at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where setup, handling, and delay allowance sits at 10% and the headline result is 11 hr, this scenario comes in 2.55% below the baseline at 10.72 hr.
  • It computes the base review time from forecast count divided by review pace, then inflates it by a setup, handling, and delay allowance to give required hours. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Required demand review workload time: 10.72 hr (headline result)
  • Base demand review workload time: 10 hr
  • Demand review workload allowance applied: 7.2 %
  • Demand review workload completion rate: 12 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Demand Review Workload calculator, set setup, handling, and delay allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.