S&OP, Demand Planning & Forecasting worked example

Supply Review Capacity Gap at 7.2% setup, handling, and delay allowance: a worked example

This worked example runs the supply review capacity gap numbers for a tougher week than the baseline: 7.2% setup, handling, and delay allowance instead of the typical 10%. Estimate supply review capacity gap 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

  • Supply plan lines to review: 120 units (held at the documented default)
  • Supply lines 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 supply review capacity gap time = supply review capacity gap workload รท supply review capacity gap completion rate.
  • Required supply review capacity gap time works out to 10.72 hr at these inputs, and this is the headline figure for the scenario.
  • Base supply review capacity gap time works out to 10 hr at these inputs.
  • Supply review capacity gap allowance applied works out to 7.2 % at these inputs.
  • Supply review capacity gap 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.
  • Use it when scheduling the supply review, testing whether headcount can absorb added resources or constraints, or scoping tools that speed constraint checking. 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

  • Required supply review capacity gap time: 10.72 hr (headline result)
  • Base supply review capacity gap time: 10 hr
  • Supply review capacity gap allowance applied: 7.2 %
  • Supply review capacity gap completion rate: 12 pieces / min

Run it with your numbers

  • To rerun this with your own numbers, open the live Supply Review Capacity Gap 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.