Let's start with the dedicated resources, the BlockRAMs, multipliers, DCMs. Global clocks, PPCs, MGTs and the general-purpose I/O. You know before you start your desigh what percentage of these resources you need, and I bet it seldom will be 100% of each of them. So here you get everything you need (or you already know you need a different, bigger chip.) That leaves us with the balancing between logic resources (LUTs, flip-flops, SRL16s), routing capabilities, and your specific needs. Routing used to be the limiting factor in the distant past, but modern FPGAs have such an abundance of routing resources that this is seldom the limitation. Performance may suffer when the chip gets really crowded, but that depends very much on your requirements.
60% sounds to me like an insanely conservative number. Butt with over
100,000 new designs started every year, there is an enormous spread, and one should never say "never". Let's settle on "extremely unlikely". With the increasing complexity available in modern FPGAs, designers also have developed a more mature attitude, realizing that some spare room is a good thing to have. 15 years ago, some cried when a few LUTs went unused: "Such a waste !". Now they say: "Nice to have some room for future changes."
Peter Alfke, Xilinx Applications