The three tools Chapter 15 walks through, in the order the book recommends using them — free, no email required.
A reliable data source should always outrank a perfectly executed workshop exercise. That's the whole argument of Chapter 15 — and these are the three worksheets it points to: run the Pareto first to find the failures that actually matter, scope the SIPOC to just those, then take the vital few into RCM/FMECA.
Download all three below — each is a working Excel file (formulas included) with a print-ready PDF alongside it.
List every failure or loss category with its count or downtime. The vital few — the small number of causes driving most of the loss — surface automatically.
Do this first. Everything downstream should be scoped to what this finds, not the other way round.
Map the process boundary AFTER the Pareto has told you which failures matter. Scoped to the vital few, not the whole department.
A SIPOC sized to the real losses stays useful. One built to look thorough gets ignored.
Take the vital few into full RCM/FMECA. Safety and environmental failure modes are managed proactively regardless of RPN — this worksheet enforces that.
Also Module 3 of the NJN PAMF Academy, for anyone who wants to go further.
Three Excel templates + print-ready PDFs. No email required.
The KPI Whisperer is the book these worksheets come from — why good people chase the wrong numbers, and what to measure instead.
See the books →