S&OP, Demand Planning & Forecasting worked example

Product Family Forecast Mix at 99% planned line uptime: a worked example

Push planned line uptime up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when product family forecast mix in s and op, demand planning and forecasting is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Sellable units built per production cycle: 4 units / cycle (unchanged)
  • Available production cycles in the plan horizon: 480 cycles (unchanged)
  • Planned line uptime (availability): 99 % (raised for this scenario; the documented default is 90)
  • Expected first-pass yield across the family: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross product family forecast mix capacity = product family forecast mix output per cycle × available product family forecast mix cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good product family forecast mix capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross product family forecast mix capacity.
  • At this operating point the engine returns 19.2 units for product family forecast mix downtime loss.
  • At this operating point the engine returns 57.02 units for product family forecast mix yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where planned line uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • It computes good sellable capacity for a product family by multiplying output per cycle by available cycles, then derating for uptime and first-pass yield. 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

  • Good product family forecast mix capacity: 1,844 units (headline result)
  • Gross product family forecast mix capacity: 1,920 units
  • Product family forecast mix downtime loss: 19.2 units
  • Product family forecast mix yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Product Family Forecast Mix calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.