S&OP, Demand Planning & Forecasting worked example

Planning Exception Load at 7.2% research, follow-up, and rework allowance: a worked example

Suppose research, follow-up, and rework 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 planning exception load 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

  • Planning exceptions raised per cycle: 120 units (held at the documented default)
  • Exceptions resolved per planner per minute: 12 units / min (held at the documented default)
  • Research, follow-up, and rework 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 planning exception load time = planning exception load workload รท planning exception load completion rate.
  • Required planning exception load time works out to 10.72 hr at these inputs, and this is the headline figure for the scenario.
  • Base planning exception load time works out to 10 hr at these inputs.
  • Planning exception load allowance applied works out to 7.2 % at these inputs.
  • Planning exception load completion rate works out to 12 pieces / min at these inputs.

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 2.55% below the baseline at 10.72 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. 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 planning exception load time: 10.72 hr (headline result)
  • Base planning exception load time: 10 hr
  • Planning exception load allowance applied: 7.2 %
  • Planning exception load completion rate: 12 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Planning Exception Load calculator, set research, follow-up, and rework allowance to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.