S&OP, Demand Planning & Forecasting worked example

Planning Exception Load at 12% research, follow-up, and rework allowance: a worked example

Push research, follow-up, and rework allowance up to 12% and the picture changes. This example computes every intermediate figure at that operating point. Use it when planning exception load in s and op, demand planning and forecasting needs a defensible run time before a quote goes out.

The inputs for this scenario

  • Planning exceptions raised per cycle: 120 units (unchanged)
  • Exceptions resolved per planner per minute: 12 units / min (unchanged)
  • Research, follow-up, and rework allowance: 12 % (raised for this scenario; the documented default is 10)

Working through the calculation

  • Applying the documented formula (Base planning exception load time = planning exception load workload รท planning exception load completion rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 11.2 hr for required planning exception load time, the number this scenario is built around.
  • At this operating point the engine returns 10 hr for base planning exception load time.
  • At this operating point the engine returns 12 % for planning exception load allowance applied.
  • At this operating point the engine returns 12 pieces / min for planning exception load completion rate.

How this compares with the baseline

  • Against the tool's baseline example, where research, follow-up, and rework allowance sits at 10% and the headline result is 11 hr, this scenario comes in 1.82% above the baseline at 11.2 hr.
  • It computes the planner hours required to work through a given count of exception messages at a known resolution rate, uplifted by a research and follow-up allowance. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Required planning exception load time: 11.2 hr (headline result)
  • Base planning exception load time: 10 hr
  • Planning exception load allowance applied: 12 %
  • Planning exception load completion rate: 12 pieces / min

Run it with your numbers

  • Every input above is editable in the live Planning Exception Load calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.