S&OP, Demand Planning & Forecasting worked example

Product Family Forecast Mix at 65% planned line uptime: a worked example

This worked example runs the product family forecast mix numbers for a tougher week than the baseline: 65% planned line uptime instead of the typical 90%. Estimate product family forecast mix for sandop, demand planning and forecasting using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Sellable units built per production cycle: 4 units / cycle (held at the documented default)
  • Available production cycles in the plan horizon: 480 cycles (held at the documented default)
  • Planned line uptime (availability): 65 % (the input this scenario stresses; the baseline uses 90)
  • Expected first-pass yield across the family: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross product family forecast mix capacity = product family forecast mix output per cycle × available product family forecast mix cycles.
  • Good product family forecast mix capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross product family forecast mix capacity works out to 1,920 units at these inputs.
  • Product family forecast mix downtime loss works out to 672 units at these inputs.
  • Product family forecast mix yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 units.
  • Use it during rough-cut capacity planning in S&OP to reality-check a product-family forecast against the line that has to build it. 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

  • Good product family forecast mix capacity: 1,211 units (headline result)
  • Gross product family forecast mix capacity: 1,920 units
  • Product family forecast mix downtime loss: 672 units
  • Product family forecast mix yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Product Family Forecast Mix calculator, set planned line uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.