TABLE OF CONTENTS
SECTION I - INTRODUCTION …………………………………………………………3
QUALITY POLICY STATEMENT …………………………………………………………4
SUPPLIER ENGINEERING MISSION STATEMENT ………………………………….…5
BASIC EXPECTATIONS ………………………………………………………...…………6
PRINCIPLES OF THE HARMAN INTERNATIONAL / SUPPLIER RELATIONS
SECTION II – QUALITY PLANNING REQUIREMENTS …...………………….……8
2.1 Concurrent Engineering
2.2 Process Flow Charts
2.3 Feasibility Assessment
2.4 Failure Mode and Effects Analysis (FMEA)
2.5 Error and Mistake Proofing
2.6 Control Plans
2.7 Gauge Planning
2.8 Preliminary Process Capability
2.9 Control of Incoming Parts and Raw Material
2.10 Process Monitoring and Control Instructions
2.11 Packaging Planning / Labeling Requirements
2.12 Ongoing Quality Planning
SECTION III – PRODUCT AND PROCESS QUALITY
3.1 Ongoing Process Capability
3.2 Statistical Process Control (SPC)
3.3 Product Monitoring
3.4 Measuring and Testing Equipment
3.5 Material Identification / Routing Identification / Lot Traceability
3.6 Reference Samples
3.7 Control of Reworked Products
3.8 Returned Product Analysis
3.9 Problem Solving Methods
3.10 Scheduled Preventive Maintenance
3.11 Continuous Improvement
SECTION IV – DOCUMENTING QUALITY ….………………..……………….……19
4.2 Records / Records Retention
4.3 Drawings and Change Control ( Document Control)
4.4 Harman International Temporary Deviation
4.5 Changes in Manufacturing Processes (Change Approval)
4.6 Quality Operating system (QOS)
SECTION V – SUPPLIER QUALITY SYSTEM REVIEW ….………………...…..…21
5.1 General Qualification Requirements
5.2 World Class Supplier Qualification Survey
5.3 Requirements for New Supplier
5.4 Requirements for Existing Harman International Suppliers
5.5 Harman International Review of Supplier Quality Systems
5.6 Harman International Supplier Quality Rating
SECTION VI – PPAP FIRST PIECE SAMPLE APPROVALS ….…………...………24
6.1 PPAP Submission Requirements
6.2 Situations Requiring Initial Sample Approval
6.3 Situations when PPAP may be optional
SECTION VII – TOOLING AGREEMENT ….…………………...………..…………28
7.1 Tooling & First Articles Due Date - Plastics
7.2 Tooling Payment - Plastics
7.3 Supplier Responsibility - Plastics
7.4 Quoting - Plastics
7.5 Quoting Requirements Tooling - Plastics
7.6 Quoting Requirements - Resin
7.7 Annual Validation
7.8 Life of Tool(s)
7.9 Obsolete Tool(s)
SECTION VIII – GENERAL BUSINESS PRACTICES
8.1 Payment Terms
8.2 Obsolete Material Claims
8.3 Electronic Data Interchange (EDI)
8.4 On-Site Review of Supplier‟s Processes
8.5 Gift Policy
8.6 Quoting Requirements - General
8.7 Contracts / Purchase Agreements
8.8 Disposition of Rejected Material
8.9 Delivery Requirements
SECTION IX – SUPPLIER MEASUREABLES / TARGETS ….……………..………34
APPENDIX A (Forms and Miscellaneous Procedures)
A1--G8D Corrective Action Form …………………..……See Forms section of Web
A2--Electronic Data Interchange (EDI) ………………… See Forms section of Web
A3--Temporary Deviation Notice (TDN) ……………….See Forms section of Web
A4--Change Request (ECR) ………………………………See Forms section of Web
A5--Non-Disclosure Agreements ………………………… See Forms section of Web
A5--Harman International ……………………………………….See Forms section of
A6--Supplier ……………………………………………….See Forms section of Web
A7--Obsolete Material Claim Forms and Procedure ………See Forms section of
A8--Supplier Performance Summary and Description …….See Forms section of
A9--Supplier BOS Quality Chart example ……………..……See Forms section of
A10-Supplier Reporting for RSRC Data (Chemical Analysis Information) See Forms
section of Web Page
A11-Monthly Cpk Summary Matrix ……………………See Forms section of Web
A12-PPAP Checklist …………………………………… See Forms section of Web
A13-Tooling Information for PPAP Checklist ………… See Forms section of Web
A14-PPAP Label ……………………………………… See Forms section of Web
APPENDIX B (Recommended Reference
TS-16949 Quality System Requirements
Advanced Product Quality Planning and Control Plan (APQP)
Failure Mode and Effects Analysis (FMEA)
Measurement Systems Analysis (MSA)
Statistical Process Control (SPC)
Production Part Approval Process (PPAP)
Chrysler Process Sign-Off (PSO)
Dimensioning and Tolerancing (GD&T)
Harman International Guidelines for Supplier Packaging
Shipping/Parts Identification Label Standards
World Class Supplier Qualification Survey
APPENDIX C Delivery Performance System
SECTION I - INTRODUCTION
This manual is applicable to all Harman International suppliers who produce or manufacture
the components; adhesives; chemicals; or sub-assemblies delivered to Harman International.
The purpose of this manual is two-fold.
1. To describe the Quality Expectations Harman International has of its suppliers.
2. To describe the business practices, and provide the forms and procedures to be used in
dealing with Harman International.
Harman International is a TS-16949 Company, and expects all of its suppliers to be TS-16949
compliant, with formal certification recommended. Much of the quality related information in
this manual is a high level summary of what is described in TS-16949. It is recommended that
all suppliers have the full set of documents listed in Appendix B, implement the disciplines
described in those manuals, and keep current with the manual updates. The customers of
Harman International have extremely high performance expectations, with the ultimate goal
being “perfection” in quality and delivery.
The business practices portion of this manual provides the supplier with an understanding of
the day to day business practices and expectations in dealing with Harman International. The
forms listed in this manual are all available electronically, so please contact the appropriate
supplier engineer (as listed on the inside cover of this manual), so that the requested form can
be e-mailed to you.
Although quality is the ultimate responsibility of the supplier, Harman International fosters
open lines of communication, provides periodic training classes, and conducts on-site auditing
and consulting as needed. The expectations are high and the competition on a global scale is
fierce. Harman International and its suppliers will be constantly challenged to improve in all
aspects of the business which affect and improve the three key factors of: Quality, Delivery,
and Total Cost.
HARMAN INTERNATIONAL, INC.
QUALITY POLICY STATEMENT
Harman OEM (HOEM) is committed to exceeding customer expectations by promoting an
environment that provides QUALITY products, services and support. CUSTOMER
SATISFACTION and a commitment to CONTINUOUS IMPROVEMENT.
President – OEM Americas / Asia Sr. Vice President Manufacturing
HARMAN INTERNATIONAL SUPPLIER ENGINEERING MISSION STATEMENT
The mission of Supplier Engineering is to establish and maintain a successful co-destiny
relationship with suppliers based on mutual trust and full understanding of Harman
International requirements and supplier capability. This will be accomplished through
teamwork with Supplier Engineering to identify and develop suppliers that share the
commitment to, and demonstrate continuous improvement, while being able to meet
delivery requirements for the highest quality product, at a globally competitive total cost.
If all companies could meet the simple, basic expectations, as listed on this page, on every
part, on every shipment, then there would be very few quality or delivery problems. Although
the list below is seemingly very simple, the items in the list represent the largest ongoing
problems that are experienced at the Harman International locations when dealing with
suppliers. Please take some time to review this list and then reflect on your own processes
and practices, and review your quality and delivery histories to see how well you are able to
meet each of these “Basic Expectations.”
1. The parts on the inside the box need to match the label on the outside of the box.
2. Subassemblies should be complete.
3. Subassemblies should contain the correct components.
4. All part features should be present.
5. Parts should arrive at their destination free from damage; warp; or deformities.
6. PPAP capability should be maintained and improved.
7. Deliver the QUANTITY requested at the TIME requested.
8. Respond to problems in time requested and provide thorough containment / root cause
and preventive actions.
9. Take full ownership of any problem situation.
10. Expect the same from your sub-suppliers.
PRINCIPLES OF THE HARMAN INTERNATIONAL / SUPPLIER RELATIONS
Supplier Co-Destiny: Harman International is committed to developing and maintaining co-
destiny relationships with their suppliers. Suppliers are responsible for on-time delivery of
quality products and services. Harman International will work proactively with suppliers to help
them meet this responsibility.
Demonstrated Supplier Process Stability and Capability: Suppliers to Harman
International must have processes that are stable and in control so that excellent product
quality can be the norm. Harman International requires suppliers to provide statistical evidence
of process stability and capability, and evidence of significant supplier quality improvements.
Quality Operating System: The Quality Operating System, or QOS, is defined as a
disciplined team approach to managing by facts. A system for the regular periodic preparation
and management review of a Quality Operating System must be in use by all Harman
International suppliers. Although the content of each supplier‟s QOS will be unique, every QOS
must include a report of ongoing capability (Cpk) for all defined significant characteristics.
Characteristics monitored should include both process and product parameters. Suppliers
should be able to discuss and prove, via actual data, the Cpk of significant product and process
Supplier Quality Systems: TS 16949 is the recognized standard to which all Harman
International suppliers need to comply. Harman International suppliers must have acceptable
quality systems incorporating recognized quality principles, including continuous improvement,
employee involvement, and customer focus. Each supplier‟s quality system will implement
these universal principles in a way that uniquely fits that supplier‟s products, manufacturing
systems, and business methods. The goal is to ensure the on-time delivery of quality products
manufactured with stable and repeatable processes.
Supplier Training: Suppliers are required to have personnel properly trained in SPC and
other key areas of responsibility. Suppliers are encouraged to obtain training in Advanced
Quality Planning, preparation of Control Plans and FMEA‟s, and development of a Quality
Operating System. Harman International will periodically make such training available to its
suppliers. This is done to help suppliers progress from defect detection toward defect
Effective Corrective Actions: Suppliers are required to have personnel properly trained in
problem solving techniques. Harman International recommends the use of Global 8D
methodologies. The supplier is responsible to apply corrective actions as applicable to all
products and processes, to prevent recurrence of similar problems on any future products.
SECTION II – QUALITY PLANNING REQUIREMENTS
2.1 Concurrent Engineering:
Early participation and involvement by suppliers in the concurrent engineering process is
encouraged at Harman International. Together, customers, suppliers, Quality, Design
Engineering, Manufacturing Engineering, Marketing, Manufacturing, and Supplier Engineering
must assure that all significant characteristics have been identified.
2.2 Process Flow Charts:
Process flow charts show the sequence of steps in the production operation, along with the
control points. Flow charts provide essential information for quality planning tools such as the
process FMEA and Control Plan.
Quality System Evidence Requirement: Flow charts of production processes.
2.3 Feasibility Assessment:
Feasibility assessment is the determination of the suitability of a particular design, process, or
material for production. All engineering requirements must be met, while maintaining required
capability, volume levels, as well as cost targets. These assessments use planning tools such a
FMEA‟s, Control Plans, process capability studies, and designed experiments. Manufacturing
feasibility should be established prior to the commitment of production tools or facilities.
Quality System Evidence Requirements: Feasibility assessments for proposed new products or
changes in processes and products.
2.4 Failure Mode and Effects Analysis (FMEA):
The FMEA process assists in the prevention of product quality concerns through a structured
analysis of potential failure modes. FMEA‟s should be used for both product design and
manufacturing process planning. They are required for all new or changed products to be
delivered to Harman International (refer to the section on PPAP first piece sample approvals).
There are three types of FMEA‟s:
Design FMEA‟s are used by the product design activity as an essential part of the
design development process. The risk of product failure is reduced by increasing
the probability that potential failure modes and their effects on system operation
have been considered in the design development process. A list of potential
failure modes is developed and ranked according to their effect on the end
customer, thereby establishing a priority system for design improvements and
development testing. Design FMEA‟s are prepared by a team from the design
activity, prior to or during the prototype tooling phase. A typical team should be
headed by the responsible design engineer, and might include representatives
from the Quality Engineering, Manufacturing Engineering, and Manufacturing
organizations, with input from a customer representative.
Prototype FMEA‟s – may be unnecessary.
Process FMEA‟s identify and evaluate the risk of occurrence of potential process
concerns, and define the actions to eliminate them. Process FMEA‟s are prepared
by a team from the manufacturing activity, prior to the commencement of hard
tooling. A typical team should be headed by the responsible process engineer,
and might include representatives from the Design Engineering, Quality
Engineering, and Manufacturing organizations, with input from a customer
representative. The design FMEA should be available during preparation of the
process FMEA, but the lack of a design process FMEA assumes the product as
designed will meet the design intent. Potential failures which can occur as a
result of a design weakness are not included in the Process FMEA. Their effect
and avoidance are covered in the Design FMEA.
Critical and significant product characteristics and process parameters identified on the FMEA‟s
become key inputs to the Control Plan.
Quality System Evidence Requirement: FMEA‟s for processes, and product designs where the
supplier has design responsibility.
2.5 Error and Mistake Proofing:
The product design and the production and/or assembly process should all be reviewed to
eliminate the possibility of errors that would result in defective product. Methods should be
developed to clearly identify errors that may occur, and prevent them from becoming non-
2.6 Control Plans:
Control Plans are developed by suppliers for all significant process parameters and significant
or critical product characteristics, as determined by the FMEA. In addition, all significant
characteristics designated by a circle-squared symbol on a Harman International drawing or
specification must also appear on Control Plans. Control Plans must be prepared and
maintained for all new or changed products, or upon specific request from Supplier Assistance
or Product Engineering, for existing products. The development of Control Plans by a cross-
discipline team similar to the FMEA team is recommended. For new or changed products, the
Control Plan must accompany the request for first piece sample approval (PPAP).
Essential elements in Control Plans are:
Control of raw material or purchased components that will be used in the product
A numbered list of each process step, with a brief description
Identification of the machines, devices, jigs, and tools used in each process step.
The classification (critical, significant, or other) of the process step, relative to the
The process monitoring methods, including process or product specification,
evaluation method, sample size, and frequency.
The analysis method or specific statistical tool (for example: P-chart or X-bar and
R-chart) to be used in control of the process. 100 percent inspection can also be
used, but its effectiveness in the particular application should be verified.
The reaction plan when out of control conditions are encountered.
Harman International Supplier Engineering will review and make suggestions on Control Plans
submitted by suppliers. Control Plans are living documents which should be revised as new
data about processes becomes available. Changes to a Control Plan should be reviewed by
Harman International Supplier Engineering.
Quality System Evidence Requirement: Current, up-to-date Control Plans, reviewed and
approved by Harman International.
2.7 Gauge Planning:
The choice of gauging, measuring, and testing equipment is a key element of advanced quality
planning. Suppliers must provide for variables data measurement wherever possible. Since
variables data provides more information content than attribute data, opportunities for process
improvement are highlighted, and process capability evaluation is simplified. Measurement
systems assessment studies (Gauge R&R) must be conducted for all gauges, measurement,
and test equipment used. Particular attention should be paid to gauges, measurement, and
test equipment used for the evaluation of Harman International designated significant or critical
product characteristics. Periodic re-calibration and maintenance should be provided as needed.
Quality System Evidence Requirement: Consideration for gauging, measuring, and test
equipment as part of the advanced quality planning process. Gauge R&R studies showing
capability in relation to the tolerance allowed.
2.8 Preliminary Process Capability:
Preliminary process capability studies are short-term studies conducted to obtain early
information on the performance of a new or revised process, relative to customer
requirements. These studies should be based on as much data as possible, but at least twenty
subgroups (for a total of at least 100 parts) are required to obtain sufficient data for informed
decision-making. For some processes, the requirement for twenty subgroups will not apply.
(For example, when individual readings, rather than subgroups, are the basis for data
gathering.) A preliminary process capability study is required for each significant characteristic
for which ongoing process capability of an existing, comparable process is unavailable, and for
any characteristics designated with a circle-squared symbol.
Data should be gathered and used to develop preliminary control limits. These limits are used
to evaluate the stability of the process. Once the process is known to be stable (no evidence of
or special causes), preliminary process potential (Pp) and preliminary process capability (Ppk)
can be estimated. [The indices Pp and Ppk are used to denote the results of preliminary
studies and to differentiate these results from ongoing process potential and capability results
denoted by the indices Cp and Cpk.] Attributes data should not be used for preliminary
The minimum acceptable outcome for preliminary capability studies, for normally distributed
processes and bilateral specifications, is that the interval consisting of the process average plus
and minus five standard deviations must be within engineering specifications. For a unilateral
specifications, plus or minus five standard deviations must fall within the relevant maximum or
minimum specification. These requirements are equivalent to a Ppk of 1.67.
Processes not meeting this minimum criterion are normally considered unacceptable for
production, and should be carefully reviewed by the supplier‟s cross-disciplinary team.
Preliminary process studies being submitted to Harman International with initial sample
approvals which do not meet this criterion must be accompanied by an action plan prepared by
the team, with target dates for corrective action.
Quality System Evidence Requirement: Preliminary process capability studies are used as part
of the advanced quality planning process, and need to be included in the PPAP submissions.
2.9 Control of Incoming Parts and Raw Material:
Approved Materials: Materials used in products for Harman International are controlled either
by industry standard specifications (e.g. ASTM, DIN, ISO, SAE, etc.) or by Harman International
customer specifications (e.g. Chrysler, Toyota). Additional sources may be specified on
Harman International drawings. Suppliers must certify that materials submitted for first piece
sample approvals meet all applicable raw material specifications and requirements. In addition,
suppliers must re-certify annually that materials shipped to Harman International meet all
applicable specifications and requirements. Periodic re-certifications must include pertinent
laboratory data substantiating the certification statement.
Control of Purchased Products and Raw Material: The supplier is responsible for the control
and quality of all sub-supplier materials. Changes in sub-supplier sourcing after initial sample
approval requires a new initial sample submission to Harman International. Key elements of a
sub-supplier monitoring and control program are:
Transmitting information on the intended application and relevant drawings,
specifications, and requirements to the sub-supplier.
Ensuring that sub-suppliers have acceptable quality systems incorporating
recognized quality principles.
Obtaining current Control Plans and evidence of their implementation from sub-
Ensuring that all sub-supplier products and raw materials conform to applicable
specifications, and verify this through an incoming audit program.
Initiating corrective action (the Eight Discipline approach is highly recommended)
with sub-suppliers on nonconforming products, and maintaining records of these
concerns with the status of corrective actions.
Quality System Evidence Requirement: A system to monitor and control sub-supplier quality.
2.10 Process Monitoring and Control Instructions:
Suppliers should prepare written process monitoring and control instructions for employees
having responsibilities for the operation of processes, in order to ensure that all monitoring and
control steps in the Control Plan are carried out. These instructions can be derived from the
FMEA and Control Plan, from engineering drawings and specifications, from manufacturing or
quality workmanship standards, or from supplier experience and knowledge of processes and
Quality System Evidence Requirement: Written process monitoring and control instructions are
developed as part of the advanced quality planning process. Audit the process and the
handling methods as well as the product.
2.11 Packaging Planning / Labeling Requirements:
The choice of packaging material can have a significant effect on product quality, and must be
considered during the feasibility evaluation phase. Suppliers must use appropriate packaging,
considering the various transportation and shipping methods used, to ensure that products
arrive safely, in a condition suitable for their intended use at Harman International. Suppliers
must also take into consideration the point of end use of their product when selecting
packaging materials, so as to minimize multiple handling and re-packing at Harman
International. The use of shipping trials during the prototype or pilot phases of product
qualification will minimize production start up problems, and is strongly recommended.
The Harman International Guidelines for Supplier Packaging and Labeling (pallet sizes; weight
limits; barcode standards; etc.) are available by calling Harman International. See Appendix B
for ordering information.
Quality System Evidence Requirement: Attention to packaging design as part of the advanced
quality planning process. Adherence to packaging and labeling standards.
2.12 Ongoing Quality Planning:
Ongoing Quality Planning includes actions taken to prevent deterioration of processes and
products from initial capability levels. These actions may include: ongoing operator training
and certification; periodic review of SPC application and effectiveness; calibration of measuring
and testing equipment; and scheduled preventive maintenance. Documented plans for ongoing
quality assurance will support the Control Plan.
SECTION III –PRODUCT AND PROCESS QUALITY
3.1 Ongoing Process Capability:
Ongoing Process Capability is a long-term measure of process performance relative to
specifications, for all critical and significant characteristics evaluated using variables data.
Ongoing process capability differs from preliminary process capability by using data taken over
a longer time period. This is done to ensure that all common causes of process variation have
been included in the observed data. The actual time period for data collection will depend on
the time necessary for these sources to vary through their full ranges, but will probably not be
less than twenty production days.
Capability is determined using data from control charts. These charts must indicate a
stable and normally distributed process before capability calculations (Cp, Cpk) can
be made. If analysis indicates a non-normally distributed process, advanced statistical tools
will be needed to determine Cp and Cpk. (Note: Cp cannot be calculated for unilateral
Harman International‟s requirement for process capability of items indicated on the print with a
circle-squared symbol is a minimum Cpk of 1.33.
BATCH PROCESSES: Control charting on a lot by lot basis should be done to determine
capability and stability over time for batch processes. This would apply where only one sample
can be obtained per mix of product; or where one group of samples has to be taken at random
from a batch of parts where it is not possible to determine any time order of production of the
individual parts in the batch.
Quality System Evidence Requirement: Process capability evaluations (Cp, Cpk) are used to
prioritize the continuous improvement effort.
3.2 Statistical Process Control (SPC):
An essential aspect of defect prevention is the use of SPC as the “language of manufacturing”
to indicate when it is appropriate to take actions affecting the process.
All critical and significant characteristics listed on the Control Plan should be controlled using
SPC. Out of control conditions should be noted and explained on all charts. Charts should be
monitored for evidence of process instability, and appropriate corrective actions taken in a
When process improvement actions are taken, relevant control charts should be used to
monitor the effects of the changes. New control limits and centerlines should be calculated
after the process has stabilized, and the new process capability should be compared to that
obtained previously. Capability trends should also be monitored, and any indication of
decreasing capability should be carefully examined, whether or not the process is
operating within specifications. Decreasing capability can be an indicator of serious quality
Certain statistical methods have been identified which are counter-productive to the philosophy
of continuous improvement, and are unacceptable as evidence of continuous improvement.
AQL sampling plans with acceptance numbers greater than 0, specification-based control
charts, and the use of pre-control.
Quality System Evidence Requirement: Use of SPC to monitor processes and prioritize the
continuous improvement effort.
3.3 Product Monitoring:
Suppliers are responsible for selecting the appropriate methods to control all characteristics of
their products. For characteristics not controlled with SPC, one or more of the following
methods should be chosen:
100 Percent product testing.
Periodic, scheduled product audits.
Outgoing product audit.
Periodic layout inspection for dimensional requirements, and laboratory tests of
relevant physical and chemical properties, performed at least yearly, or according
to an approved Control Plan.
Quality System Evidence Requirement: Selection and documentation of appropriate methods
to control all product characteristics. Annual layouts and recent (< 12months old) material
certifications available upon request. Results of product monitoring must be available for
review within 8 hours of Harman request and may be required to be submitted with shipments.
3.4 Measuring and Testing Equipment:
Suppliers must provide adequate gauges and measuring and testing equipment to ensure that
all process control requirements outlined in the Control Plan can be maintained. Gauges,
measuring, and testing equipment should provide variable data wherever possible.
Measuring and testing are themselves processes, and are therefore sources of variation.
Appropriate statistical studies (gauge repeatability and reproducibility) must be conducted to
identify sources of measurement variability, and determine if the processes of measurement in
use are stable. Appropriate measurement systems assessment criteria must be chosen for
each specific measurement application.
Suppliers must develop and implement a plan to verify the accuracy and stability of
measurement systems with sufficient frequency to ensure the integrity of those systems.
Actions taken can include stability studies, Gauge R&R, periodic preventive maintenance, and
periodic calibration. Traceability to national reference standards must be provided; where no
such standards exist, the basis for calibration must be documented.
Quality System Evidence Requirement: Adequate gauges, measuring and test equipment to
ensure process control. Gauge R&R Study for all circle square dimensions to be part of the
3.5 Material Identification / Routing Identification / Lot Traceability:
Suppliers must identify the condition and status (accept, reject, hold, sort, rework, etc.) of
product through all stages of the production process by means of tags, stamps, color codes,
routing tickets, or other control methods. Positive controls should be developed to ensure that
unique products for Harman International are properly identified and do not become mixed
with other products.
Where product goes through multiple processing steps, the material should be identified to
ensure that the product does not miss any processing steps and to avoid the possibility of
having unfinished product shipped to Harman International.
Suppliers are required to have lot traceability system in place which is capable of identifying
and containing product based on lot # specified on the shipping box label. Traceability must
go from finished product lot # back to date of manufacture and identification of all raw material
lot #‟s that were used in the product.
Quality System Evidence Requirement: Systems in place for the identification of product status
and lot traceability.
3.6 Reference Samples:
Suppliers must retain a portion of production runs submitted for first piece sample approval,
(no less than 2 pieces for mechanical components), to provide a reference when full
production is initiated. Similarly, when first piece inspection is used to qualify a new production
set-up, the first piece should be retained throughout the production run.
Quality System Evidence Requirement: The supplier maintains reference samples.
3.7 Control of Reworked Products:
“Rework” consists of any actions taken on the product which are not a part of the usual
production process. Since any action to repair or salvage a product which does not originally
meet customer requirements is a source of special cause variation, Harman International‟s goal
is the elimination of all such actions.
When rework is necessitated as an interim containment measure, the supplier must develop
written procedures for the rework operation. These procedures must provide for relevant
monitoring, inspection, and testing steps after rework, in order to ensure conformance to all
applicable requirements. Passing the reworked product through the normal production
monitoring system, wherever practical, is preferred. Procedures for rework to product
which Harman International supplies as a completed end item to our customers
(e.g. amplifiers) must be approved in writing prior to commencing rework
Quality System Evidence Requirement: Reworked product must be noted in writing designated
through written procedures for rework operations. Written procedures for rework operations
and identification of material that has been reworked.
3.8 Returned Product Analysis:
As an essential area of customer focus, the supplier is responsible for analysis of parts returned
by Harman International for any reason. Records of the results of these analyses must be kept
and made available to Harman International upon request. Supplier should use the Global 8D
Problem Solving method (8D process) to initiate containment and corrective action in response
to a Harman International Defective Material Notice (DMN).
Quality System Evidence Requirement: Examples of returned parts documentation and
3.9 Problem Solving Methods:
Harman International recommends the use of the Global 8D Problem Solving method (8D
process) to ensure consistent communication of concerns. This approach should be used
whenever internal (e.g. process issues) or external (customer report) indicators show that a
quality concern exists. An example Eight-Discipline format is included in Appendix A-1.
Steps in the Eight-Discipline approach are:
1) Establish Team
2) Describe the problem
3) Develop the Interim Containment Action (ICA)
4) Diagnose Problem: Define and verify root cause and escape point
5) Choose and verify Permanent Corrective Actions (PCAs) for root cause and escape point
6) Implement and validate Permanent Corrective Actions (PCAs)
7) Prevent recurrence on similar processes/products
8) Recognize team and individual contributions
Quality System Evidence Requirement: Use of Eight-Discipline approach for quality concerns.
3.10 Scheduled Preventive Maintenance:
Routine preventive maintenance can contribute significantly to process stability and
repeatability, and reduce the frequency of emergency repairs to production equipment and
tooling. Suppliers must develop and maintain a documented system for the routine preventive
maintenance of production equipment and tooling. Manufacturer‟s recommendations, expected
tool wear, and trends indicated by analysis of SPC data should be considered in developing and
operating this system.
Quality System Evidence Requirement: Planning for preventive maintenance of production
equipment and maintaining a log of Preventive Maintenance activities on equipment and
3.11 Continuous Improvement:
Suppliers should use the Quality Operating System (QOS) process to identify continuous
improvement priorities and to provide measurables of progress within the supplier organization.
Examples: supplier average Cpk, number of significant characteristics charted, number of
characteristics in control.
Quality System Evidence Requirement: Plans for improvement; results as documented in a
QOS; monitoring Cpk on a month by month basis for proof of continuous improvement. Cpk
reporting matrix form is included in Appendix A-11.
SECTION IV – DOCUMENTING QUALITY
Suppliers should develop, implement, and maintain written procedures to define all aspects of
their quality system requirements for the control and continuous improvement of product
quality. Each of the topics in sections II through VI of this Standard should be covered in these
TS-16949 is the recognized standard to which all suppliers should comply.
Quality System Evidence Requirement: Documented quality procedures; TS-16949
4.2 Records / Records Retention:
The supplier must keep adequate quality systems records, including FMEA‟s, Control Plans,
operating instructions, measurement system assessments, product test methods, and records
of test equipment maintenance and calibration.
The supplier must also keep quality performance records including control charts, test results,
and periodic product evaluation results. Quality performance records must be retained
for one full calendar year after the date of generation. Initial sample approval
reports (PPAP’s) must be retained for one calendar year after the production of the
part is discontinued. These records must be available for review.
Quality System Evidence Requirement: Quality system and quality performance records.
4.3 Drawings and Change Control (Document Control):
Suppliers must have the latest engineering drawings, specifications, and authorized Temporary
Deviation records and ensure that all relevant personnel are aware of Harman International
requirements. The supplier should maintain current copies of all external documents (e.g.
ASTM specifications) referred to by Harman International drawings and specifications.
Suppliers are responsible for establishing and maintaining a system to ensure the orderly and
controlled management of design and process change. Concurrent with the effective dates of
authorized product changes, the supplier must ensure that obsolete information is removed
from all points of use. The supplier must maintain a record of all Harman International
authorized changes and their respective effectivity dates.
Quality System Evidence Requirement: Documented drawing and design change control
methods; current editions of reference documents.
4.4 Harman International Temporary Deviation:
When Harman International Quality pre-authorizes a Temporary Deviation for product or
process characteristics, the supplier must maintain records of the quantities deviated and the
expiration date of the deviation. This is to ensure that the conditions of the deviation are not
violated. The Temporary Deviation number should be shown on each shipping container.
Suppliers who are requested by Harman International to ship product having any
nonconformance from specifications must obtain a pre-authorized Temporary Deviation for the
product or process characteristics in question, prior to shipping. Failure to do so can result
in the issuance of an Incoming Rejection, which has a negative impact on the supplier‟s quality
The information above applies to requests made BY Harman International to have the supplier
ship known nonconforming material. If however, during the course of ongoing production, the
supplier finds nonconforming material and wants Harman International to provide a temporary
deviation, then the supplier will have to come to Harman International to walk around the
deviation request to obtain the required signatures for approval. The supplier will also have to
provide a corrective action (8D) as part of the deviation request.
Quality System Evidence Requirement: Documented records of Harman International
A Temporary Deviation Notice (TDN) form is included in Appendix A-3.
4.5 Changes in Manufacturing Processes (Change Approval):
Process improvements by Harman International suppliers are expected, as part of the process
of continuous improvement. However, after a product has been approved via the PPAP
process, then there can be no changes to the processes or materials (including changes of sub-
suppliers) used to produce that product, without notification and agreement from Harman
International. Harman International may request that a new PPAP be submitted with the
proposed process or material change. Review Section 6 of this Supplier Manual to determine
when formal PPAP submissions are, or may be, required.
Supplier initiated changes to design or process must have written Harman International
approval prior to any tooling modification or production incorporation of process or
design changes. Formal PPAP first piece sample submission and approval will also be
required prior to implementing the change into production.
Quality System Evidence Requirement: Documented records of application for and receipt of
Harman International PPAP approval. Engineering Change Request (ECR) form is included in
4.6 Quality Operating system (QOS):
The Quality Operating System, or QOS, has been defined as a disciplined team approach to
managing by fact. A system for the regular periodic preparation and management review of a
Quality Operating System should be in use by all Harman International suppliers. Although the
content of each supplier‟s QOS
will be unique, one common feature should be a report on overall capability, in the form of a
factory process capability (Cpk) status report on significant characteristics. Key measurables
for the particular supplier‟s business should be defined, goals and action plans established, and
progress toward those goals regularly evaluated. Response to customer concerns should be
one of the areas of focus chosen, with action plans developed jointly between the supplier and
Quality System Evidence Requirement: A system for the periodic preparation and management
review of a supplier‟s key measurables, with particular focus on customer concerns and
SECTION V – SUPPLIER QUALITY SYSTEM REVIEW
5.1 General Qualification Requirements:
Harman International suppliers must have acceptable quality systems incorporating recognized
quality principles including continuous improvement, employee involvement, and customer
focus. The way in which these basic principles are implemented will be unique to each
supplier‟s products, manufacturing methods, and business systems. The intent, however,
remains constant: to ensure the on-time delivery of quality products at an ever decreasing
cost. Harman International Supplier Engineering is responsible for reviewing supplier Quality
Systems to determine that qualification requirements are met.
NOTE: All suppliers to Harman International are expected to be TS-16949 compliant, with
formal certification recommended.
5.2 World Class Supplier Qualification Survey:
Harman International focuses on developing meaningful measurables for suppliers, as
documented in their QOS, which indicates demonstrated results. Supplier Engineering will
meet periodically with suppliers to monitor progress on action plans.
Each supplier must themselves complete and return to Supplier Engineering, a Harman
International World Class Supplier Qualification Survey form. The intent of this process is for
the supplier to define the areas needing improvement, address them with action plans, and
track results. The self-survey process will be most effective if the supplier acts as their own
worst critic. This survey may be used as the basis of Harman International audit.
See web page (forms section) for information on the World Class Supplier Qualification Survey.
5.3 Requirements for New Suppliers:
When a supplier does not currently provide products to Harman International, the Harman
International Supplier Engineering organization will forward to the supplier, a World Class
Supplier Qualification Survey. The survey questionnaire must be completed and scored by the
supplier after conducting a self-survey. The self-survey questionnaire will be evaluated by
Harman International Supplier Engineering, and a determination made as to the adequacy of
the supplier‟s Quality System. Based on the self-survey evaluation, a supplier may be asked to
prepare a corrective action plan, and report progress on actions taken. A new supplier will not
be able to sell production product to Harman International until the supplier‟s Quality System
has been found to be acceptable.
The self-survey and qualification review process must be completed prior to the
awarding of any purchase order or contract to a new supplier. Note that this
process qualifies only suppliers, not parts. Components, parts, subassemblies, and
materials from qualified suppliers must be approved individually, using the PPAP first piece
sample approval process detailed in Section VI of this manual.
5.4 Requirements for Existing Harman International Suppliers:
Suppliers currently doing business with Harman International are considered to be qualified
based on past experience and quality history, unless otherwise notified in writing by Harman
International. All such existing suppliers must conduct a self-survey and complete and return
to Supplier Engineering a copy of the self-survey of the World Class Supplier Qualification
Survey questionnaire. Existing suppliers may be asked to perform a re-self-survey every
twelve months (12 months), or at the discretion of Supplier Engineering.
5.5 Harman International Review of Supplier Quality Systems:
The Harman International Supplier Engineering organization may, at the request of the
supplier, or at their own discretion (based on supplier performance and responsiveness to
concerns) conduct and score the World Class Supplier Qualification Survey at the supplier‟s
production location(s). Reasonable notice will be provided of the intent to conduct a review of
the supplier‟s Quality System. The purpose of this review is to further Harman International‟s
understanding of a supplier‟s capabilities, to improve the awareness of the interactions
between the supplier‟s processes and Harman International‟s, and to observe the supplier‟s
continuous improvement efforts.
5.6 Harman International Supplier Quality Rating:
Suppliers are expected to deliver quality products produced by stable and repeatable
processes. Since suppliers are required to provide statistical evidence of process stability and
capability, it should be unnecessary for Harman International to police received materials. It is
the intent of Harman International to use incoming audit of supplier material on an exception
basis only, when indicted by part quality history or process capability.
Harman International suppliers are rated on several key areas of their performance. This
rating measures a supplier‟s ability to comply consistently with Harman International
requirements, and assesses its management commitment to the continuous improvement
process. An adverse supplier rating can affect the contracting of any new business, and the
continued sourcing of existing business. The overall supplier rating is made up of the following
PPM Rating. Ratio of parts rejected vs. parts received.
Delivery Rating (DPR‟s). Shipping demerits for over/under; early/late
Response Rating. Responses expected within 24 hours of
Monthly Cpk reports. Submission of monthly Cpk Summary Report.
Primary production suppliers will receive a monthly Supplier Performance Summary Sheet
which shows the performance for the current reporting month, as well as a cumulative
performance for the model year. An example of this Summary Sheet is included along with
explanation, in Appendix A-8.
For suppliers having performance in the lower tier of the supply base, a further breakdown in
quality related information is provided to and reviewed with the supplier. An example of this
chart is also included in Appendix A-9. This format is a useful standard that could also be
adopted for a suppliers internal reporting on quality problems and trends.
SECTION VI – PPAP FIRST PIECE SAMPLE APPROVALS
The purpose of the PPAP sample approvals is to confirm that all drawing and specification
requirements are met by the parts submitted, and that the supplier has used the necessary
advanced quality planning tools to ensure that the products and materials shipped to Harman
International will be the result of stable and capable processes.
Suppliers are held accountable for the on-time delivery of quality products for initial sample
review and approval. Failure to meet scheduled PPAP dates could seriously impact Harman
International‟s delivery commitments to its customers. It is expected that PPAP‟s be complete
and that the supplier will make every effort to meet the design specifications prior to
submission so that the PPAP can be approved on the first pass. If there are dimensional issues
on part design, the time to address these is in the Concurrent Engineering phase, prior to
tooling the part. Engineering Change Requests can be reviewed as part of the PPAP
submission, but these only delay the approval process.
Harman International follows the AIAG Production Part Approval Process (PPAP) guidelines for
part approvals. There are also additional items that Harman International needs to have as
part of the PPAP submission. A complete listing and description of the PPAP submission
expectations is listed below. A PPAP Checklist summary is included in Appendix A-12 and A-13
of this manual.
6.1 PPAP Requirements:
This is a full listing of the requirements for a full level 3 PPAP submission. Depending upon
the reason for submission, there may not be a need for each of these items to be submitted
for all PPAP‟s. Please see the PPAP Matrix in Appendix A-12 for which items are required and
what level of submission is required for prototype; production; annual submission; or part
Requirements per AIAG PPAP Manual - CURRENT Edition
1. Design Records
Bubbled print (each item on the print to be numbered, including dimensions; notes;
material callouts; and any specifications listed on the print).
If submitting an assembly, then a print of each Harman International component
also needs to be included.
2. Engineering Change documents (if any).
Any authorized engineering change documents not yet incorporated in the design
record but incorporated in the part. This would be for instances where the tooling
has been updated per an approved engineering change prior to the print being
updated to reflect those updates.
3. Customer Engineering Approval
Needed only when there is a note on a Harman International print which specifies
that design engineering approval is required. It would be rare that this would be
included on new part prints.
4. Design FMEA
If the supplier designs the component or assembly being purchased by Harman
International, then the supplier needs to submit a DFMEA. Purchased tweeters
would be an example.
5. Process Flow Diagrams
6. Process FMEA
7. Dimensional results
Three (3) pieces inspected complete to print.
If multi-cavity, then one (3) parts complete to print per cavity.
Each item bubbled (numbered) on the part print needs to be included in the layout,
including notes; material identification; etc.
8. Material, Performance Test Results
Results of testing that shows the material to meet specifications identified on the
part drawing. This would include both material specifications (as in a Material
Certification of Conformance) and any performance, durability or environmental
This would include material certifications, which should show the detail of the
requirements and the actual results. If the material needs to meet a particular
specification, then the supporting documentation should state that specification
number on the material certification.
9. Initial Process Capability Studies
Data to show conformance for characteristics noted as significan on the part print.
For variables measurement data on components, supporting data should include
control chart (25 subgroups of 4 or 5 samples) which shows process to be in control.
30 piece capability study with Cpk > 1.33. Cpk based on the control chart data is
For multi-cavity tooling or batch processes, data needs to be presented separately
for each cavity. This would include 30 pieces for each cavity. Batch processes
should present data from 30 pieces for components, or show material certification
for each lot of material for product such as adhesives.
10. Measurement System Analysis Studies (ie. Gauge R&R)
Minimum of 10 pieces, measured 2 times by 2 operators.
Target is 10% to 30% of the tolerance. < 10% is preferred.
To be included for each significant characteristic.
Measurements should be taken on the parts, or very similar parts as being
submitted in the PPAP. Tolerances, gauges, fixtures, type of part, feature being
inspected are all part of the measurement “system.”
11. Qualified Laboratory Documentation
This is a laboratory scope which shows the training; equipment; qualifications of the
lab that is providing the dimensional data for the PPAP.
12. Control Plans
Including all product and process-related significant characteristics.
13. Part Submission Warrant (PSW)
All information in the PSW needs to be completed, including weight or part and run
rate of process.
14. Appearance Approval Report
Only if part has color, grain, or some other cosmetic appearance requirements
specified on the part print.
15. Bulk Material Requirements Checklist (not used for Harman International)
16. Sample parts:
Layout samples clearly identified. Usually two (2) samples for layout or one per
Supplier to keep a “master” sample.
Submit 300 pieces unless requested specifically for a different quantity.
Boxes should be marked with the Blue PPAP label.
17. Master Sample
Supplier to keep a “master” sample. One piece from each cavity if multiple cavity.
18. Checking Aids
If the supplier uses inspection aids (ie. Mylars for inspecting gaskets; or resonance
clamps for inspecting cones), then a duplicate inspection aid should be sent with the
19. Records of Compliance With Customer-Specific Requirements
This applies to Section II of the PPAP manual. This does not apply to suppliers
submitting PPAP to Harman International.
Additional Requirements specific to Harman International
20. RSRC Chemical Analysis Information
See the RSRC section of the Harman International Suppler Manual
21. Tooling Information
See the information which follows
Tooling Information Required with PPAP Submission
All Harman International tooling used to produce the product being submitted for approval
requires the following tooling information included with the PPAP Submission. The following
information is needed before final payment for tooling will be made. A copy of the Approved
PPAP needs to be included with the tooling invoice in order to be paid for tooling.
1. Digital photographs of each tool – supplied in CD format (JPEG, TIFF format).
2. Diagram of strip layout if the tool is a progressive die. – CD Format
3. Tool drawings of each tool (Per section 7.2 & 7.3 of this supplier manual)
4. Tool cost breakdown for each tool by:
Design cost (Included with PPAP)
Material cost (Included with PPAP)
Labor cost (Included with PPAP)
5. Complete description of each tool. (eg. 2 cavity, hot runner, P20 injection mold with no
6. Dimensions of tool.
Daylight opening size if injection mold
Weight of tool
Number of stations if Progressive or Transfer Die
7. Type of material used for the tool. (IE: P-20 with H-13 insert and Ampco in hi heat areas)
8. Press size used to run the tool.
9. Cycle time of Tool (Part to Part)
10. Capacity of the tool.
11. Life expectancy of tool in number of parts.
The information listed above needs to be included as part of the PPAP package for part
approval and is required prior to final tool payment. If there is a tooling modification to an
existing tool, then there needs to be a description of the tooling modifications and a
breakdown of the costs associated with this modification and a new strip layout diagram if this
is affected. The updated information must be submitted with the updated PPAP submission.
RSRC Chemical Analysis
The customers of Harman International are requiring recycling information on the components
that are used in their cars and trucks. In order to comply with the recycling information, it is
necessary to provide certain chemical compositions and weight information on the components
included in the speaker assemblies. The spreadsheets included in Appendix A-10 further
explain the requirements and includes a spreadsheet for reporting the RSRC Information.
6.2 Situations Requiring PPAP Submission:
Initial sample approvals (PPAP‟s) are required prior to all first production quantity shipments of:
A new part or product (i.e., a specific part, material, or color not previously supplied
to the specific customer.)
Correction of a discrepancy on a previously submitted part.
Product modified by an engineering change to design records, specifications, or
Additionally, suppliers must notify the customer and submit for part approval prior to
the first production shipment in the following situations unless the responsible part
approval activity has specifically waived this requirement for the subject part. If the
customer waives a formal submission, all items in the PPAP file must be
reviewed and updated, as necessary to reflect the current process. The
PPAP file must contain the name of the responsible part approval activity
person granting the waiver and the date.
6.3 Situations when PPAP may be optional:
For the following instances, the supplier is required to notify Harman International, but PPAP
may be optional. Harman International will decide on a case by case basis whether PPAP
should be submitted for these instances.
Use of another optional construction or material than was used in the previously
Production from new or modified tools (except perishable tools), dies, molds,
patterns, etc., including additional or replacement tooling.
Production following refurbishment or rearrangement of existing tooling or
Production following any change in process or method of manufacture.
Production from tooling and equipment transferred to a different plant location or
from an additional plant location.
Change of source for subcontracted parts, materials or services (e.g.,: heat-treating,
Product re-released after the tooling has been inactive for volume production for
twelve months or more.
Change in inspection or test method.
The purpose of these requirements is to identify changes that might affect the direct customer
or ultimate purchaser of the vehicle or component.
Primary suppliers are responsible for subcontracted material and services.
IF THERE ARE ANY QUESTIONS CONCERNING THE NEED FOR PRODUCTION PART
APPROVAL, CONTACT THE RESPONSIBLE SUPPLIER ENGINEER.
SECTION VII – TOOLING AGREEMENT
The following information relates to the process that needs to be followed on tooling orders, tool payment terms,
required tool identification and approval through production and service and finally into obsolescence. As well is
Harman - Becker NAFE‟s expectations and requirements for tooling build and components including resin.
7.1 Tooling & First Articles Due Date:
1. The due date listed on a tooling purchase order is the date in which a full Level III PPAP is to arrive at
Harman - Becker NAFE for approval. Level of PPAP is defined as what is referenced in the current AIAG
PPAP Manual. Suppliers shall include all Level III PPAP documentation as required by Harman - Becker
2. Unless specified otherwise by a Harman - Becker NAFE Supplier Quality Engineer (SQE) a quantity of 300
pieces is required with each PPAP submission. The 300 pieces should be included with the cost of the
tooling. A separate PO will not be issued for set-up & run of the 300 pieces required for PPAP.
3. In some instances where1st articles are required prior to PPAP / 1A – this date will be called out in the
tooling PO as „first shots required‟ and the awarded supplier will be responsible to meet the date and
quantity of parts required by the plant for all build events. Part quantities will be negotiated prior to
award and per piece cost on a separate or on the tooling PO.
4. Timing to 1st shots will be defined as: from the receipt of final CAD data by the supplier.
7.2 Tooling Payment
1. Tooling payment terms will be paid 20% with Purchase Order, 80% upon successful submission and
acceptance of PPAP and all related items.
2. Included with the PPAP package will be all final or as built tool designs, CAD surface files and CAD design
files. Files are to be submitted in IGES format and burned on a CD or CD‟s prior to final payment.
Surface files shall include all parting line files, slides, lifters, electrodes and any other feasibility studies in
reference to construction of the mold. Mold design files shall include all views, sections, details, B.O.M.,
press/platen swing studies, electrical wiring schematics, hydraulic plumbing schematics, water plumbing
schematics in reference to the construction of the mold. Also, any mold flow analysis completed are to be
submitted in Powerpoint format or another readable and acceptable format. Suppliers must denote on the
CD in what data media format the files are in. Failure to adhere to this request will result in the final
payment being late or withheld until all data is received at Harman - Becker NAFE.
3. Suppliers are not to invoice for tooling reimbursement until a copy of the approved PPAP cover sheet can
be attached to the invoice and sent to Harman - Becker NAFE. Upon receipt of the invoice with PPAP
approval attached, final balance payment will be made prox 60 from receipt of supplier invoice.
4. All parts are expected to meet all print specifications upon initial PPAP submission. Tooling modifications
required to bring any parts up to print specifications shall be the responsibility of the awarded supplier.
Feasibility to manufacture must be mutually agreed upon in writing prior to tooling kick off.
5. Any print tolerance or dimensioning issues must be corrected prior to submission of PPAP. Any costs
associated with providing a „part to print‟ will be the responsibility of the awarded supplier.
7.3 Supplier Responsibility
1) All tools should be designed to run automatic. Automatic is defined as the ability of the part to de-
gate during ejection and the parts and runner to fall freely from the mold without operator
assistance. Exceptions must be approved in writing by the appropriate Harman - Becker NAFE
Purchaser, Supplier Quality Engineer(SQE) and prior to tool construction in the form of vendor sign-off /
approval to tool. It will be the responsibility of the production supplier to maintain records of evidence for
tooling approvals at each stage.
2) All tool designs are the property of Harman - Becker NAFE and shall not (in total or in part) be given to
another company or duplicated without written approval of Harman - Becker NAFE.
3) The awarded supplier will be responsible for the submission of a tool progress report every week as
designated by the Tooling engineer/Purchaser and will begin one (1) week after award or receipt of PO.
4) Life of Tool; Awarded production supplier is responsible to properly store and maintain all tooling
throughout planned and quoted production life of the program as referenced in the RFQ, plus 10 years
(which includes service requirements).
5) Awarded suppliers must complete the HBAS Tool Information Sheet (TIS) for each tool purchased. A copy
of the TIS form can be found on the Harman - Becker NAFE Supplier Web Page in the forms section. All
information required must be completed. The TIS form shall be submitted in Excel format on a CD with
the PPAP submission and also sent to the responsible Harman - Becker NAFE purchasing organization or
1. In an effort to reduce cost and realize savings through effective utilization of Harman – Becker NAFE‟s
global sourcing power, Harman - Becker NAFE reserves the right to negotiate and source resin and
tooling on behalf and/or in conjunction with the awarded production supplier for all plastic commodities.
In every instance tooling must be built to meet and/or exceed the awarded production suppliers build
standards for all tooling. In addition all tooling PO‟s will be issued to the awarded production supplier. It
shall be the awarded production suppliers‟ responsibility to manage the agreed upon tool builder and
ensure all tooling meets or exceeds their tool build requirements.
7.5 Quoting Requirements – Tooling (Plastics)
1. Steel certification and dimensional certification for all tooling and gages/check fixtures should be included
in tooling quotes.
2. A mold Flow Analysis may or may not be required and will be at the discretion of the Harman - Becker
NAFE Supplier Quality Engineer. (SQE) or Mechanical Engineer (ME). A Mold flow analysis should be
itemized on all quotations for each tool.
3. Sufficient tryouts must be included in the quoted cost to provide tryouts through PPAP plus any required
run-at rate or HVPT trial. A Minimum of 3 tryouts, plus 1 through graining may be required and should be
itemized and included with the cost of each tool quoted.
4. 300 piece part sample submitted with PPAP submission to be included with the cost of each tool and shall
include all shipping and packaging costs.
5. Additional 300 Pieces required for various build requirements prior to PPAP / 1A to be included in the cost
of the tool. A separate discrete PO will not be issued to production suppliers to cover this cost. Costs
associated will be assumed as part of the tool costs and shall include all shipping and packaging costs.
6. 30 Piece Capability Study included in cost of tool. This may be negotiated out if not required as
determined by a Harman - Becker NAFE ME and Purchasing.
7. 3 part layout per cavity / per part. Layouts to be performed according to dimensions on the print and
included in tool cost.
8. If graining/texture is required, tool supplier must cover tryout cost within the cost of the tool and until
grain approval is given.
9. Quote is to include an additional set of spare heaters and thermocouples for hot drop/hot runner manifold
systems itemized on the quotation and included in cost of tool.
10. DME style date wheel must be used whenever possible for all parts awarded. Location to be called out in
11. A shot counter which can not be reset must be recessed within tool and covered with a plate to protect
12. Part Identification: All Parts must be marked with Part Name, Part Number & material type on the outside
of the part and able to be clearly read. Location of part identification should be listed on the part
drawings or CAD. IF not called out on drawing - approval of location for part identification must be given
in writing by Harman - Becker NAFE designer or Program ME.
13. Tooling is to be properly tagged for identification and ownership purposes. Pictures of the tags attached
to the tooling are required with PPAP submission. NOTE: Some Harman International customers may provide a
separate tag to be attached after tooling payment by the customer. This tag will be separate and in addition to the information
listed above. If this additional customer information is required, then it will be provided to the supplier by Harman International.
14. Harman Tool Identification Requirements: All tools shall have the following information marked on all
tooling, stamped, engraved or on a plaque affixed to the operator side;
Harman – Becker
Part Name or Description
Harman - Becker Part #
Tool Builder / Company Name / address / phone
16. All engineering change quotes shall include transportation, 1 tryout, 50 parts and a 3 part layout as
17. Awarded production supplier must supply a weekly, monthly, quarterly and yearly Preventative
Maintenance schedule for each tool. This information is to be submitted with PPAP documentation. CD or
paper format is ok.
18. Tolerances shown on the part drawings are part tolerances only and must not be utilized for mold
19. Dimensional steel certification must be provided prior to first shots unless agreed upon by
Harman - Becker NAFE SQE or ME in writing. All critical points must be checked per drawing
call outs. Points are to be supplied by the Harman - Becker NAFE SQE or ME or as called out
in the drawing(s). Unless noted otherwise, CAD is master for each part.
20. All exceptions with regard to tolerancing must be noted on all quotes and approved in writing by Harman
- Becker NAFE SQE, ME and Purchasing prior to mold construction.
21. After all requirements for production and service have been met, the supplier may ask for permission to
scrap the tooling. This must be a written request sent to Harman International purchasing. Purchasing
will review the request with the Harman International customer to determine if any future requirements
may be needed. If it is determined that the tool is obsolete, then permission will be given in writing to
scrap the tool. Harman International reserves the right to come on-site at the supplier location to observe
the scrapping of the tool.
22. The supplier is expected to perform a full dimensional layout annually to ensure continued conformance
to all part print specifications. This layout needs to be available upon request as part of an annual PPAP
submission. If the tool in question is an inspection fixture then annual calibration is required.
23. Any part concessions or part tolerances in question must be addressed prior to cutting of steel or
approval to tool is given by a Harman Becker ME or Purchasing Engineer. Any changes required AFTER
tooling is complete to provide a “part to print” will be the responsibility of the awarded production
A sign-off by a Harman - Becker NAFE employee does not alleviate the awarded tooling supplier of the
responsibility for designing and building tooling which meets or exceeds the requirements and related
items listed in this manual, as well as the requirements of the awarded production supplier. The awarded
production supplier is responsible for the following, at a minimum: cosmetic appearance of the part as
defined by the production requirements (i.e. no ejector pins through surface, successful ejection without
pin push), fit and function of the part and to meet all specifications on the related CAD and drawing(s) -
providing a part that meets all requirements and tolerances as called out.
7.6 Quoting Requirements - Resin
Harman Becker‟s required practice for RFQ‟s and quoting expectations are outlined below;
1. Any drawings not specifically calling out „100% virgin material‟ and/or „no regrind allowed‟ - are to be
quoted using 100% virgin material with no regrind allowed as the standard practice for calculating
2. As we progress through the negotiating phase of each program with regard to tooling and piece
price, if at that time there is an opportunity to use regrind in any or all of the parts being reviewed, it
will be at Harman Becker‟s discretion on a case by case basis to review the proposed % of regrind.
Specifically the responsibility will be that of the Program M.E. and in conjunction with purchasing of
reaching a decision with each supplier.
3. For Production Validation (PV) builds, plastic parts are to be supplied both with 100% virgin material
and no regrind as well as with the proposed percentage of regrind as may have been discussed
during the negotiation phase of the program with the ME and Purchasing.
4. Piece cost should be itemized on quotations and clearly defined with regard to proposed % amount of
regrind. Costs for both 100% virgin material and with allowable % of regrind must be shown.
5. Documentation throughout the life of program must be maintained by the supplier regarding lot
traceability and % amount of regrind used in each lot. The supplier must be able to prove % of
regrind used in the event of a part failure during production.
6. The amount of regrind should not exceed that as called out in suppliers quote and as may be listed
on the Blanket PO.
7. Depending on the agreed to % of allowable regrind it is to be understood and agreed to by the
respective Harman Becker supplier that clean, in process generated regrind, proportioned evenly back
into the process feed shall only be allowed. Runners and scrap pieces from the respective
parts/program being run should only be used as regrind. In no circumstance shall recycled material
be purchased to meet the allowable regrind percentage nor should parts from other programs being
run of the same material be used.
8. The supplier‟s PPAP submission must reflect compliance to the allowable percentage of regrind and
any parts presented for PPAP approval must include the agreed to percentage of allowable regrind, so
that PV testing validates parts representative of typical production. In no circumstance should 100%
virgin material be used for PPAP part submission and then production parts contain a % of regrind.
Failure to adhere to this requirement may result in financial penalties being assessed in the event of a
part failure during production.
9. Where regrind is used, % regrind must be a FMEA item and must include corresponding control
methods within the control plan. Positive control of regrind will be heavily weighted during PPAP
control and will be grounds for PPAP rejection if control is not demonstrated.
7.7 Annual Validation:
The supplier is expected to perform a full dimensional layout annually to ensure continued
conformance to all part print specifications. This layout needs to be available upon request as
part of an annual PPAP submission. If the tool in question is an inspection fixture, then annual
calibration is required.
7.8 Life of Tool:
Supplier is responsible to properly store and maintain the tool throughout production life of the
program, plus 10 years (which includes service requirements).
7.9 Obsolete Tooling:
After requirements for production and service have been met, then the supplier may ask for
permission to scrap the tooling. This must be a written request. Harman International will
review the request with the Harman International customer to determine if any future
requirements may be needed from this tool. If it is determined that the tool is indeed
obsolete, then permission will be given in writing to scrap the tool. Harman International
reserves the right to come on-site at the supplier location to observe the scrapping of the tool.
SECTION VIII – GENERAL BUSINESS PRACTICES
8.1 Payment Terms:
Payment terms for production components and sample parts will be net 60 days paid
approximately on the 1st and 15th of the month. Timing on the 60 days starts after receipt of
the parts at the Harman International dock. Individual supplier incentives for early payment
(eg. 2% discount if paid net 10 days) will be considered on a case by case basis.
Payment terms for tooling; A copy of the PPAP approval needs to accompany the tooling
invoice in order for the invoice to be processed. Tooling payment terms are: “20% down with
Purchase Order, Balance Prox 60 from PPAP Approval”. Tooling payments will be made
approximately 60 days from receipt of the invoice. Partial tooling payments will not be made at
intervals during the tool build cycle. Harman International will pay 100% of the balance of
tooling costs after the parts from the tool are PPAP approved.
8.2 Obsolete Material Claims:
From time to time, primarily at the end of program life, or when there is an engineering change
made that obsoletes down level parts, there will be surplus material that will need to be
scrapped. In the production contract, or in the purchase order for each part, there will be a
listing for authorized inventory levels of raw and fab material. If the program ends abruptly,
then Harman International is responsible for the cost of the inventory up to the limits agreed
upon. If the supplier has produced product, or procured raw material that goes beyond the
agreed upon limits, then the supplier is responsible for any inventory exceeding the agreed
upon limits. Only claims in excess of $500 will be allowed.
EXAMPLE # 1: If the limits of stock are agreed to be 4 weeks fab and 4 weeks raw, then the
supplier can have any combination of material not to exceed 4 weeks worth of requirements as
shown on the Harman International production release schedules. This could be in the form of
4 weeks of finished goods and 0 weeks of raw material; or 2 weeks of finished goods and
enough raw material to be able to make another 2 weeks of finished goods; or even 0 weeks of
finished goods and enough raw material to make 4 weeks of finished product.
EXAMPLE # 2: If the limits of stock are agreed to be 4 weeks of fab and 6 weeks of raw, then
the liability is limited to 4 weeks of product as shown in the production release schedules. An
additional amount of raw material capable of producing 2 weeks of finished product would be
also be allowed in this example. This would amount to the 4 weeks of finished goods plus the
2 weeks worth of raw material, for a total of 6 weeks. The raw and fab amounts are not
Appendix A-7 contains the complete procedure on how to file a claim for obsolete material.
Also included in A-7 are the appropriate claim forms and a listing of the documentation that
needs to be included when filing a claim.
It is expected that the supplier will make every effort to minimize the amount of
material at the end of a program. This will be accomplished through close
communications with Harman International production control to work out balance
out quantities. Also, only that raw material which is
unique to Harman International, and which cannot be used on any other supplier
product will be considered for reimbursement.
The RPS schedule is the official document authorizing product manufacture and shipments. If
the schedule shows 0 requirements, then the supplier needs to call Harman International to
inquire about the status of the component. If no formal notice of obsolescence is received and
the schedule suddenly drops to 0 for an extended period, then the supplier should contact
Harman International production control, verify the material requirements, and file any
applicable claims in a timely manner. A timely manner would be considered as within 2 months
of the schedule going to 0, if the supplier is not otherwise notified of end of production for a
8.3 Electronic Data Interchange (EDI):
The preferred method of distributing production releases is via EDI. Suppliers are expected
establish the EDI links to Harman International to be able to receive the production releases
electronically. GE Information Services (GEIS) is Harman International‟s preferred EDI supplier.
Contact information and a general letter of EDI expectations is included in Appendix A-2.
8.4 On-Site Review of Supplier’s Processes:
Periodically it will be necessary to visit a supplier‟s production location to review quality issues;
perform the World Class Supplier Qualification Survey; or just to review new product plans. It
is fully expected that representatives from Harman International will have access to the
production areas of the supplier and sub-suppliers and be able to review the processes used in
making the parts and/or raw material.
Harman International representatives will not sign a non-disclosure agreement without prior
approval from the Harman International legal department. However, a sample of an approved
non-disclosure agreement is included in Appendix A-6 of this manual which Harman
International representatives can sign at the supplier‟s location if it is required by the supplier
to do so.
Also, the supplier may be asked to sign a non-disclosure agreement so that discussions;
drawings and other documentation is kept confidential between the supplier and Harman
International. The “Supplier Non-Disclosure Agreement” is included in Appendix A-5 of this
8.5 Gift Policy:
The following summary is offered as a general guideline to follow in the normal course of
Harman International/Supplier Relations. It is expected that the use of good individual
judgement be followed in all cases, with the expectation being that if one is unsure about
whether something should be acceptable, then it should probably be avoided or not accepted
or offered. There should be no situation in which it could be viewed by anyone that a business
lunch; promotional item; etc., provides an unfair advantage for one supplier over another.
Business meals with supplier/customer are acceptable for normal business
discussions. The philosophy of Harman International is that meals should be paid for
on a reciprocating basis.
Attendance at sporting events, shows, etc., as the guest of the supplier, is allowed
no more than once a year. The hosting company representative should be present.
The use of a supplier to provide goods or perform work of a personal nature is
strongly discouraged, even though paid for by the Harman International employee.
Travel and overnight accommodations paid for by the supplier are not allowed.
Travel in a supplier‟s plane must have Supplier Engineering management approval.
Personal financial assistance of any kind is not allowed.
Promotional material or a gift of nominal value (not to exceed $25) may be accepted
if made voluntarily and there is no reasonable likelihood it will influence the
judgement or actions of the Harman International representative in performing
duties for Harman International. When not accepting a gift of greater value would
be discourteous, the gift will be turned into the Supplier Engineering manager for
8.6 Quoting Requirements:
Harman International has a formal (RFQ) quote package. The intent of this package is to be
able to receive as much information as possible to accurately differentiate quotes received from
competing suppliers. Cost breakdowns on components and tooling are required as specified in
the quote package. The breakdown requested will vary by commodity. A copy of the RFQ
package is not included in this manual and will be sent to the supplier when quotes are
requested. The supplier may be asked to sign a non-disclosure agreement (included in
Appendix A-5 of this manual) as part of the quoting process.
Harman International sends out quotation packages on an annual basis to determine global
market competitive total cost of a product. Each supplier, at a minimum, will be requested to
requote their current business. In addition, the supplier may be asked to quote on other jobs
for possible new business. The production volume requirements of all Harman International
locations are combined in this quoting effort.
8.7 Contracts / Purchase Agreements:
For production purchases, Harman International will issue a blanket purchase order to cover all
releases as specified in the Harman International production release schedules. In addition,
Harman International will use a Purchase Agreement with a production supplier which specifies
a period of time and a fixed price for which the supplier will provide product to Harman
International, along with a forecast of expected (but not guaranteed) annual volumes of the
product being purchased. A copy of a boilerplate Purchase Agreement is not included in this
manual, but will be provided by Supplier Engineering when warranted.
8.8 Disposition of Rejected Material:
If the supplier has product that is rejected at Harman International, a defective material notice
(DMN) will be issued to the supplier. For small quantity and dollar value rejects, Harman
International will take the liberty of scrapping the components to the supplier, notifying the
supplier of the reject charge, and closing the issue. Quantity scrapped will count towards a
supplier‟s PPM rating.
Containment action is expected within 24 hours of notification or receipt of samples.
Containment should discuss the handling of parts in stock at the supplier, parts in transit, as
well as date codes of parts in stock at Harman International that are suspect.
The supplier is expected to reply to Harman International within 24 hours of notification if a
DMN is issued that requires a response. The supplier should be able to provide an RMA# and
disposition authorization for handling the material. Digital pictures can be taken and sent via e-
mail to help describe the defect. As a last resort, and only if the defect is unique from past
rejects from the same supplier, actual samples can be sent to the supplier for review prior to
disposition. In this case, 24 hours from receipt of the samples will be allowed for disposition of
the parts. If no response is received within the requested time frame, Harman International
will return the parts to the supplier with an authorization of “Delay.” Suppliers will be debited
for inbound freight charges at $.10 per pound, and material will be returned collect freight to
Depending upon the urgency of the requirement for the product, Harman International may
require the supplier to sort parts on-site at Harman International. The supplier will be expected
on-site the morning after notification and will be expected to arrange for any required
additional temporary labor to assist in the sorting process. The supplier will be responsible for
supervising the temporary help and will be required to be on-site to supervise at all times
during the sorting process.
Every DMN, other than those scrapped out as low quantity and dollar value, will require an 8D
response from the supplier. 8D‟s should be received within 5 working days of notification of
8.9 Delivery Requirements:
The supplier is expected to deliver product on time, 100% of the time, and in the quantity
specified in the production release schedules. Delivery problems can lead to an eventual loss
of business. Response to delivery problems (DPR‟s) is expected in the same timeframes as
responses to defective product. The supplier is expected to provide corrective actions detailing
how delivery problems will be solved.
See Appendix C for detail on the delivery performance system.
SECTION IX – SUPPLIER MEASUREABLES / TARGETS
PPM < 25 PPM
Delivery 100% on-time; 100% of quantity ordered. There are
various levels of demerits for % over/under and days early/late.
TS-16949 Supplier should be TS-16949 Compliant. (Certification
Cpk Reports Supplier should supply monthly Cpk summary.
Globally Competitive Supplier should be globally competitive in terms of quality,
delivery and total cost.
Response Time Containment actions within 24 hours of reject notification.
8D within 5 days of rejection notification.
Minority Content The customers of Harman International strive for 5% of
purchases to come from minority suppliers. Harman
International is working towards this goal and encourages its
suppliers to support minority suppliers as well. This is not a
measurable at this time, but it is a goal that is encouraged.
Forms and Miscellaneous
The following forms, procedures, and general information items are included in Appendix A.
are to be used as appropriate when communicating with, or reporting to Harman International.
These forms are all available in electronic format available on the Web page in the Forms
NOTE: See the Web Page for all of the following:
A1 Global 8D Report
A2 Electronic Data Interchange (EDI) Contact Information
A3 Temporary Deviation Notice (TDN)
A4 Change Request (ECR)
A5 Harman International Non-Disclosure Agreement
A6 Supplier Non-Disclosure Agreement
A7-a Obsolete Material Claim Procedure and Approval Form
A8-a Supplier Performance Summary Sheet (along with descriptive information)
A9 Supplier BOS Chart example (will be seen only during Harman
International/Supplier Quality Reviews)
A10-a Supplier Reporting for RSRC Data (Chemical Analysis Information)
A11 Monthly Cpk Summary matrix
A12 PPAP Checklist
A13 Tooling Information for PPAP Checklist
A14 PPAP label (Blue Label to put on outside of boxes containing PPAP samples)
Recommended Reference Material
Automotive Industry Action Group (AIAG) Manuals:
The AIAG Manuals can be ordered by calling AIAG at 248-358-3003.
TS-16949 Quality System Requirements
Advanced Product Quality Planning and Control Plan (APQP)
Potential Failure Mode and Effects Analysis (FMEA)
Measurement Systems Analysis (MSA)
Statistical Process Control (SPC)
Production Part Approval Process (PPAP)
TS-16949 Quality System Assessment
Chrysler Process Manual
The PSO Manual can be ordered by calling Xerox Corporation; attn. Forms Manager, at 248-
Xerox Business Services / 1146 Rankin / Troy, MI 48083
Process Sign-Off (PSO)
The Process Sign-Off Manual (PSO) is an excellent review manual to use as a final
checklist/sign-off prior to going into full production. If used as an internal review by the
supplier, it is a very useful process to follow to make sure all the plans and
documentation are in place, and the process is ready to support full volume production.
Harman International reserves the right to conduct PSOs at suppliers
Geometric Dimensioning and Tolerancing (GD&T) Manual
The GD&T Manual can be ordered by calling ASME at 1-800-843-2763.
Dimensioning and Tolerancing
Delivery Performance Review System
Delivery performance will be integrated into our Supplier Performance system which currently
tracks quality performance (PPM), delivery discrepancies (DPR), responsiveness, and process
control CPK. The delivery portion carries a weighed value of 30% of your total score.
Four categories of non-performance are measured: short shipments, late shipments, over
shipments, and early shipments. Every item/release scheduled has 100 points of credit.
If an item/release is received perfectly in regards to quality and arrival date, 100
points of credit is awarded. Each category penalizes you performance: 20 demerits for
short shipments, 40 demerits for late shipments, 10 demerits for over shipments, and 10
demerits for early shipments. Exhibit 1.1 provides definitions of each penalty.
Suppliers are expected to achieve 100% on-time delivery. Delivery performance less than 90%
requires a written corrective action plan submitted to John Baughn and Cliff Petersohn with a
copy to your material Control Representative. Exhibit 1.2 provides a summary of all DPR
codes and penalties. Exhibit 1.3 provides detail of the delivery calculation.
Product Parameter Update
To insure proper delivery credit is issued basic product information is required. The auto DPR
system measures exact quantities ordered vs. delivered and packaging information is critical to
your performance. For all products you supply to Harman International we require the
Standard container packs- quantity per carton or container.
Dimensions of your cartons or containers.
Lead times for all products supplied to Harman International. The number of
work days required from the time you receive our release to the time your
product is ready to ship. You need to consider all your internal order processing,
manufacturing, and packaging times.
Wooden skid sizes must be a maximum 42"L x 45W" x 45"H as standard.
Returnable dunnage will be specified by design needs.
See Exhibit 1.4 for data entry sheet. Please fill out one sheet for each product you supply to
Automatic Delivery Performance Review
"Auto DPR System"
Integrated supplier delivery tracking system within HP CMI purchasing system. Auto DPR
system will use open releases due vs. actual material receipts to track supplier on-time
SHORT demerit (-20 points):
We receive a quantity less than expected for the requirement due date (actual cum scheduled
receipts are less than actual cum scheduled requirements).
LATE demerit (-40 points):
We receive nothing on a date for which we had a requirement due date, or we receive a
quantity less than expected on a date which we had no requirement, but supplier still past due
(actual cum scheduled receipts are still less than actual cum scheduled requirements).
OVER demerit (-10 points):
We receive more than expected on a date with a requirement (actual cum scheduled receipts
are more than cum scheduled requirements).
EARLY demerit (-10 points):
We receive more than expected on a date with no requirement (actual cum scheduled receipts
are more than scheduled requirements).
Summary of all DPR Codes and Penalties
CODE DESCRIPTION DEMERIT VALUE
07 Early Receipt -10
08 Late Receipt -40
04 Over -10
06 Short -20
01 Box Count Error-Over Packing Slip Quantity -5
02 Box Count Error-Under Packing Slip Quantity -10
03 Ship Quantity Over Release 5% Or Less -5
05 Ship Quantity Under Release 5% Or Less -15
09 Damaged Receipt Supplier Error -10
11 Box Contents Do No Match PO -15
12 Labels Do Not Match PO Part Number -5
13 Packing Slip Does Not Match PO -5
14 No Packing Slip -10
15 Unknown Parts Shipment -5
16 Pallets Exceed Size Limitations -5
17 Packaging Does Not Meet Specifications -5
18 Individual Packages Exceed Weight Limits -5
Delivery Rating = (((DRD x 100) + DPR Demerits) / (DRD x 100)) x 100
Where: DRD = Different Receipt Dates for each release
The Delivery Rating uses the demerits (positive and negative) assigned to suppliers through the
Delivery Performance Review (DPR) function. The number of different receipt dates for the
time period (typically one month) is added to the total value of the demerits, then divided by
the total number of receipt dates. A maximum value of 100% is possible.
In the above calculation, "DRD" represents "different receipt dates". Each release receipt date
is multiplied by 100 to convert maximum points possible per release date, and added to the
total value of demerits given. This value is then divided by the number of different receipt
dates multiplied by 100; the result is converted into percentage (%) by multiplying by 100.
Item Master Maintenance Sheet
Harman International Part Number:
(Max 60 characters)
(from release receipt to ship- indicate work days)
(if applicable- indicate in days)
(if applicable- indicate format)
(unit quantity per box)
Box Gross Weight:
(gross box weight)
Box Tare Weight:
(tare box weight)
(length of box)
(width of box)
(height of box)
(unit quantity per pallet load)
Pallet Box Count:
(box quantity per pallet load)
Pallet Gross Weight:
(gross pallet load weight including pallet)
Pallet Tare Weight:
(tare pallet load weight including pallet)
(length of pallet load including pallet)
(width of pallet load including pallet)
(height of pallet load including pallet)
(optional- if available)