Supplier Quality Handbook

Good Quality Is Good Business

This handbook is intended to help production material suppliers understand Knoll’s

expectations for supplying top quality components. It includes an overview of

Knoll and the company’s approach to doing business, along with the procedures,

required documentation and expectations for supplier quality.

Our goal is to deliver cost-effective products of outstanding quality to our customers on time.

Knoll’s Supplier Quality Handbook is designed to ensure that our suppliers understand their direct

role in an achieving that goal. If there are any questions or situations that do not appear to be

covered by this handbook, they should be addressed with the appropriate Knoll representative.

Good Quality Is Good Business

This handbook is intended to help production material suppliers understand Knoll’s

expectations for supplying top quality components. It includes an overview of

Knoll and the company’s approach to doing business, along with the procedures,

required documentation and expectations for supplier quality.

Our goal is to deliver cost-effective products of outstanding quality to our customers on time.

Knoll’s Supplier Quality Handbook is designed to ensure that our suppliers understand their direct

role in an achieving that goal. If there are any questions or situations that do not appear to be

covered by this handbook, they should be addressed with the appropriate Knoll representative.

Supplier Quality Handbook

Contents 04 Company Information

05 Multicultural Program Statement

06 Environmental Policy

07 Environmental Purchasing Specifications

08 Quality Policy

09 Purchasing Policy

10 Supplier Quality PPAP Process

11 Supplier Quality Documentation Requirements

19 Ownership Of Quality

20 Discrepant Material Procedure

21 Supplier Corrective Action Request

22 Supplier Rating

23 Working Together For Continuous Improvement

24 Supplier Checklist

25 Knoll Contact Information

All photographs are copyright of Knoll, Inc. All forms shown are only samples of completed documents. Data is shown only for illustration.

This Supplier Quality Handbook is designed to be and shall be interpreted as non-binding statements of intention. The written agreements between the parties will outline the rights, duties and responsibilities between the parties. Knoll expressly reserves the right to do business with suppliers and to amend or terminate its relationship with its suppliers as it deems appropriate, with or without notice.

Click on any topic to go directly to that page

04 Company Information

Good Design Is Good Business

Since its founding more than 60 years ago, Knoll has helped customers realize the value of design in the modern office. Knoll and its supplier partners have a tradition of working closely with its customers to create solutions to meet their specific needs. Knoll’s design approach, founded on careful listening and innovative thinking, considers the potential of new inventions, the impact of new materials and the emergence of new workplace models.

Design integrity has been Knoll’s guiding principle.Knoll is firmly committed to sustainable design and environmentally responsible manufacturing. Knoll structures the company around the belief that strong, healthy relationships make for strong, healthy business.

Sharp and stylish, Knoll has established an international reputation for design leadership in the furniture industry. Knoll’s products and furnishings have been revolutionizing the workplace and the home since the 1940’s. Knoll creates a comprehensive range of high-quality furniture products, textiles and accessories that offer choice and value to its customers.

Knoll office systems offer choice at every level, from the method of organizing space to the location of power and data support at the desktop. Knoll’s office systems furniture can define or adapt to virtually any office environment. Knoll designs its systems to stand the test of time: non-obsolescence is a core goal of Knoll designers.

Knoll designers have played a leading role in chair design for 65 years. This tradition of integrated engineering and aesthetics continues in Knoll’s collection of seating today. Knoll seating offers superior ergonomic support, comfort and quality at every level and for every use, from executive and task chairs to seating for conference and meeting rooms and reception areas.

Knoll storage products maximize storage capabilities without compromising available workspace. They can be used as stand-alone furniture, in conjunction with other Knoll office systems or even in open-plan or collaborative workplace environments. Knoll also creates stand-alone and adjustable desks, as well as conference, training, café, and dining tables.

These specialty products of Knoll reinforce its commitment to design leadership by offering customers a portfolio of modern classics and contemporary innovations for the workplace and include KnollStudio®, KnollTextiles™, KnollExtra®, and Spinneybeck®.

Knoll’s commitment to service is an integral part of every facet of its business.

Knoll measures service in the customers’ terms – what they want, when they want it. Reliability. That’s how Knoll sustains the innovation, service, and design vision that define the Knoll experience.

Knoll operates four manufacturing sites in North America – one in Pennsylvania, one in Ontario, two in Michigan and two in Italy – all of which are ISO 9001:2000 and 14001 certified. Knoll also has two manufacturing facilities in Italy. Knoll has implemented a culture of continuous improvement throughout its product development and manufacturing operations, targeting quality and customer satisfaction. Knoll’s Lubin facility in East Greenville, Pennsylvania has earned a Gold Level LEED® (Leadership in Energy and Environmental Design) certificate from the U.S. Green Building Council.

Company InformationReturn to Table of Contents

Multicultural Program Statement 05

Knoll acknowledges its role in the support of small and disadvantaged businesses in meeting its customer’s needs.

Knoll believes that pursuing diversity in its supply chain advances economic opportunity, enhances the communities in which it operates, supports its overall business objectives, and promotes the development of innovative business solutions, which benefit its customers.It is Knoll’s policy to select and purchase from suppliers who offer the greatest value. Within this general policy, Knoll will make a reasonable effort to ensure that small, HUBZone (Historically Underutilized Business Zone), disadvantaged, woman-owned, veteran-owned, service-disabled veteran and multicultural businesses have an equitable opportunity to compete for contracts as suppliers of materials and services to Knoll. The Multicultural Program and its goals are some of many factors in Knoll’s supplier selection process. Certifications by federal and/or independent agencies with jurisdiction are gathered as part of the program. Knoll encourages eligible suppliers not certified to become so.

Knoll routinely seeks to solicit and develop its relationships with small, HUBZone, disadvantaged, woman-owned, veteran-owned, service-disabled veteran and multicultural businesses by offering support in engineering, design, information systems and other business assistance programs. These offerings are consistent with those available to all suppliers of subcontracted materials and services to Knoll. In addition, Knoll works to identify candidates and opportunities for these suppliers with the National Minority Supplier Development Council and the Women’s Business Enterprise National Council.

Multicultural Program Statement

Life™ Chairs

Return to Table of Contents

06 Environmental Policy

Knoll’s Environmental Principles

• Protection of the Biosphere: Knoll is committed to helping safeguard all habitats affected by its operations.

• Sustainable Use of Natural Resources: Knoll strives to make the best use of natural renewable resources, such as water, soil and forests, and to conserve non-renewable natural resources.

• Waste Reduction and Disposal: Knoll reduces, recycles and disposes of all waste using safe and responsible methods.

• Conservation: Knoll conserves energy by improving the efficiency of its internal operations and the goods and services it sells, and by making efforts to use environmentally safe and sustainable energy resources.

• Risk Reduction: Knoll strives to minimize the environmental, health and safety risks to its associates and communities where it operates.

• Safe Products and Services: Knoll reduces and, where possible, eliminates the use, manufacture or sale of products and services that cause environmental damage as well as health or safety hazards. Knoll will inform its customers of the environmental impact of its products and use independent testing to help assure the safety of its products.

• Environmental Restoration: Knoll complies responsibly with the law to address conditions it has caused that endanger health, safety, or the environment.

• Informing the Public: Knoll complies with the law to inform, in a timely manner, those who may be affected by conditions caused by its operations that might endanger health, safety or the environment and encourages its associates to report dangerous incidents or conditions to management.

Environmental Commitment

Knoll has a proud history of environmental activism and responsibility. At Knoll, environmental responsibility is an ethic. Each year Knoll strives to embrace a higher standard of environmental activism and sustainability, measuring the ecological effects of materials, processes and products.

Environmental Policy

Knoll products are synonymous with functional and aesthetic excellence. Knoll is a leader in policies and practices designed to help protect the biosphere, conserve natural resources and reduce waste. Knoll aims to reduce waste in its operations, to recycle material in its products and operations and to dispose of all waste using safe and responsible methods. Knoll reaches out and aligns with third-party certification organizations, including GREENGUARD™, LEED®, FSC, and the International Organization for Standards (ISO).


Environmental Purchasing Specifications 07

Knoll expects its suppliers to be environmentally conscious by working with Knoll during the development process to investigate appropriate material alternatives. As part of Knoll’s program to enhance the sustainability attributes of its products, Knoll will request certain information about each product, including product recycled content (both post-consumer and post-industrial), Material Safety Data Sheets (MSDS), and product wood certification (categories A, B and C). Suppliers will be sent a request form on which they submit the information at the appropriate time. For new product launches, this information is required as part of the First Article Inspection Report (FAIR) submission before production approval is given.

A supplier must also meet the following Purchased Part Environmental Specifications:

CommodityFormaldehyde Emission

Factor (EF) (ug/m2 hr)Comments

Fiberglass (low density) 46.5

Fiberglass (high density) w/ attached mat

50.0 - 70.0

Particle board 456 - 659Emission rate will vary based on thickness

Plastic laminate 41.5

Gatorply backer 90

Environmental Purchasing Specifications

Indoor Air Requirements

The following average formaldehyde emission factors are required for the commodities listed below.

Note: Adhesive and coating shall be supplied without added urea or phenol formaldehyde.

Material Recycled ContentPost Consumer

Recycled Content

Steel 25% - 30% 16%

Aluminum Extruded Aluminum Cast

20% 70%

n/a

Paper products 75% 75%

Wood products 80% - 100% Greater than zero

Plastic products 10% 10%

High Density Polyethylene (HDPE) 95% 70% - 75%

Recycling Requirements

All production materials supplied shall meet the minimum recycled content as listed below.

Note: If noted on the applicable engineering drawings, major parts shall be stamped with a composition code for future recycling. The Society of the Plastics Industry (SPI) resin identification code shall be used. Major plastic part refers to a main part of the component and is integral to the design of the component. For example, items considered as a major component would be an overhead bin door, pencil trays or base cover.

The following controlled wood categories shall not be used in the manufacture of Knoll purchased products:• Wood harvested from forest areas where traditional or

civil rights are violated.

• Wood harvested from non-FSC certified forest areas having high conservation values that are threatened or not managed using sustainable forest practices.

• Wood harvested from primary tropical moist forests that are not managed using sustainable forestry practices as verified by an independent third-party audit.

• Wood harvested from intact forests as defined by World Resources Institute’s (WRI) Global Forest Watch mapping as they are developed.

• Wood harvested from primary forests in temperate or boreal forest regions that are not managed using sustainable forestry practices as verified by an independent third-party audit.

• Wood harvested from genetically modified (GM) trees.

• Illegally harvested wood.

• Natural forests that have been converted to plantations or non-forest use.

Reff® Private Office


08 Quality Policy

It is the policy of Knoll to deliver Total Quality goods and services and that all associates perform their duties with a customer-focused attitude and Total Quality consciousness.

General Quality Requirements

All materials used in part manufacture shall satisfy current legal and regulatory requirements for restricted, toxic and hazardous substances applicable to both the location of manufacturing and location of the customers. Knoll will define, as necessary, the specific requirements for volatile organic compound (VOC) emissions and the recycled content of products to meet customer needs.

Packaging methods and materials used by the supplier must ensure satisfactory protection against damage, contamination and corrosion during shipment. Knoll will define specific packaging requirements and materials when necessary. Labels for Knoll products received from suppliers need to have the following information:

• Knoll part number

• Knoll part revision level

• Quantity in box

• Knoll purchase order number

• Supplier manufacture date or lot code

Supplier Quality Expectations

Supplier quality design and manufacturing systems should prioritize defect prevention above defect detection. Both countermeasures should be confirmed on a regular basis to ensure that good products are consistently supplied to Knoll. Sub-suppliers should also be held to the same quality expectations and it is the responsibility of the tier-one supplier to ensure that that these expectations are met, which include the following items:

• Zero defects

• On-time deliveries

• Competitive prices

• Technical support

• Statistically based continuous improvement implementations

Quality Policy

Engineering Drawings

• Standard dimensions and tolerances

• Critical dimensions and tolerances as indicated by the ellipse symbol around certain dimensions on the drawing

• Raw material requirements, including Material Certifications supplied by raw material suppliers

• Notes and/or special processing instructions

• Any other applicable information to ensure a solid design

Knoll Quality Assurance Requirements (QAR)

• Developed with the supplier to ensure that the quality expectations are clearly defined and agreed upon and include such things as color, texture, visual details and items that are better quantified in words than with numbers.

Testing Requirements

• BIFMA (Business & Institutional Furniture Manufacturers Association) as provided and indicated by Knoll Engineering for each specific supplied part.

• Knoll testing requirements as provided and indicated by Knoll Engineering for each specific supplied product.

At Knoll, Quality is defined as “conformance to requirements” that are comprised of engineering drawings, Knoll QAR’s and testing requirements.


Purchasing Policy 09

It is expected that all suppliers will provide economic benefit to Knoll’s supply chain and understand Knoll’s customer needs. In addition, while Knoll seeks a mutually beneficial relationship with all its suppliers, it reserves the term “partnership” for those special relationships continually characterized by:

• A joint commitment to information exchange, planning, continuous improvement and cost reduction • Agreed-upon measures of key performance factors that are met. • The sharing of risk to achieve mutual benefits • The supplier maintaining a leadership position in technology, service and cost • The supplier being actively involved in Knoll’s new product design and development • The willingness of the supplier to enter into a contractual agreement that clearly demonstrates their complete responsibility for their product • The execution of a Knoll Purchasing Agreement

Knoll expects each of its associates to adhere to the Knoll Quality Policy - the expectation of its suppliers is nothing less. Knoll’s associates are given every opportunity to succeed. Suppliers will also be given that opportunity; as partners, suppliers own a portion of the responsibility in creating that opportunity.

Knoll’s customers demand that it stay ahead of the competition with better quality, leadership in design, and shorter leadtimes.

An absolute requirement is the delivery of 100% complete, correct, and on-time goods and services that meet or exceed expectations.Strong supply-chain communication will help to create a win/win/win relationship between our suppliers, Knoll and our customers.

Supplier Selection Requirements

Potential new suppliers will be evaluated on, among other things, their capability to meet Knoll’s requirements of Quality, Cost and Delivery. Knoll’s supplier selection is based on the following items:

• Completion of a “Supplier Self-Assessment Profile” form which is then submitted to Knoll for review.

• A supplier’s industrial experience and capability to meet the needed processes to ensure the supply chain will be as strong as it can be.

• Evaluation of the supplier to assess its acceptability in regard to factory conditions, technical capabilities, quality systems, environmental and multicultural programs, as well as commitment to improvements in Quality, Cost and Delivery. • Communication and ease of doing business. • The demonstrated ability of the potential supplier’s to be cost- competitive and deliver products on time to its customers on a consistent basis.

Once selected, a Knoll production material supplier will be expected to maintain the same high level of capabilities throughout the relationship.

Paperwork Requirements

To ensure proper receipt of goods and timely payments to its suppliers, Knoll requires the following information to be clearly indicated on these documents:

Purchasing Policy

Paperwork Requirements Packing Lists

Invoices

Valid Knoll Purchase Order (Each purchase order number must be invoiced separately)

✔ ✔

Line Item Number (Multiple items not recommended per invoice)

✔ ✔

Knoll Part Number ✔ ✔

Quantity Shipped/Unit of Measure ✔ ✔

Ship To Address ✔ ✔

Supplier Name and Address ✔ ✔

Packing List Number ✔ ✔

Unit Price, Extended Price ✔

“Bill To” must be Knoll address as indicated on PO ✔

Payment Terms ✔

Any product that will ship directly to another supplier or customer of Knoll requires notification to the purchaser within two (2) business days. Copies of packing lists and bills of lading will be required.

Documentation that does not include this information can result in delayed payment or possible return of inaccurate invoices.


10 Supplier Quality PPAP Process

Knoll utilizes the Production Part Approval Process (PPAP) with its suppliers to ensure that the parts supplied will be of the best quality. Detailed documentation on PPAP is available for purchase at the Automatic Industry Action’s Group website at www.aiag.org. Blank forms can be provided by Knoll, or the supplier may use its own existing forms if agreed upon by Knoll. Overviews of Knoll’s quality Documentation Requirements that directly relate to supplier activities and to parts supplied to Knoll are described in the following sections. The sample documents shown are only for reference and do not reflect any actual data.

These requirements have been created to provide a consistent method to monitor the quality of the products and services from Knoll’s supplier base in accordance with ISO 9001:2000 requirements.

A supplier’s compliance with these procedures is essential to both companies’ success.All quality documentation shown is developed during the preproduction phase of a new project, a tool or process relocation, or changing of a supplier for an existing Knoll product, and will be updated by the supplier when any engineering, process or quality specification is changed throughout the life of the product. These changes will be reviewed by Knoll for approval prior to implementation. Knoll works closely with its suppliers and these submitted documents are utilized to ensure that good products are consistently supplied to Knoll.

Supplier Quality PPAP ProcessReturn to Table of Contents

Supplier Quality Documentation Requirements 11

Supplier Quality Documentation Requirements

All parts and components purchased for Knoll produced parts must adhere to the Knoll Quality General Requirements and the completed documentation submitted to Knoll as outlined below.

1. Process Flow Diagram

2. Process Failure Modes Effects Analysis (PFMEA)

3. Process Control Plan

4. Gage Repeatability and Reproducibility (R&R) Study

5. Material Certification

6. Appearance And Color Approval

7. 30 Piece Capability Study

8. Part Submission Warrant

9. First Article Inspection Report (FAIR)

10. Production Part Dimensional Report



Cut Tube (tubing saw)

Bend Tube(tube bending machine)

Wrap and Pack

Rework Scrap

Ship to CustomerFinal

InspectionPowder Coat

(automatic coating line)

Bake(automatic coating line)

Wash for Paint(automatic coating line)

Weld(robotic weld machine)

Punch Holes(punch press machine)




De-Burr Tube (reamer and wire brush)



Stamp Plate(stamping press)


Rework Inspection

Supplier Quality Documentation Requirements, Continued

1. Process Flow DiagramA visual map of the production process showing inputs, outputs and units of activity, including decisions, receiving, shipping, planned inspection, rework or repair.



Control Plan Date: 5/18/06

6/1/06

6/13/06

SizeFrequency(how often?)

1Incoming Raw

MaterialReceiving

Supplier Material Certification Sheet

1 Lot Supplier monitoringOrder replacement Raw Material

Height Gauge 3 Lot Die maintenance Die adjustment

Calipers 3 Lot Die maintenance Die adjustment

Go/No Go Gauge 1 100% Die maintenance Replace punch

Calipers 1 per hour Measurement Saw adjustment

Micrometer 1 Lot incoming inspectionOrder replacement material

4 De-Burr Tube Grinder Visual check 1 100% Visual check Operator correction

Special Gauge 3 Lot Special gauge Machine adjustment

Special Gauge 3 Lot Special gauge Machine adjustment

6 Punch Holes Punch Press Go/No Go Gauge 1 100% Operator gauge Replace punch

Visual check 1 100% Visual check Adjust robotic welder

Tinius Olsen 3 Lot Special test Adjust robotic welder

8 Wash for Paint Paint Line Visual check 1 100% Visual check Adjust washer jets

Visual check 1 100% Visual check Adjust paint machine

Spectrometer 3 Lot Spectrometer Adjust color mixture

10 Bake Oven Paint line 1 100% Machine sensor Adjust oven temperature

11 Final Inspection Operator Visual check 1 100% Visual check Product put on HOLD

12 Wrap & Pack Operator Visual check 1 100% Visual check Re-work

No visual defects or weld spatter None allowed

Part correctly wrapped per Knoll QAR-054

Paint color match per Knoll QAR-018

Paint completely baked 275° ±10°

All grease and oil removed No grease/oil allowed

All areas covered with paint No missing paint

Weld in 4 places as indicated on print ±0.100"

Weld Tear Strength > 1500 lbs each weld

24.5 degrees ±0.1°

0.500" diameter ±0.005"

No burr allowed n/a

36.750" ±0.020"

20.67" ±0.10"

0.875" diameter +-"0.15"

1.750" ±0.010"

3.938" ±0.012"

Methods

per part drawing; 1016 cold rolled steel

per material certification

2.000" ±0.015"

Machine, Device,Tooling for Mfg. Speicifcation Tolerance

Characteristics

PROCESS CONTROL PLAN

Evaluation/Measurement Tool

Control Method to Meet Specification

Reaction Plan if Characteristic is Out of

Specfication

SamplePart/ProcessNumber

Process Name/ Operation

Description

Control Plan Number

Part Number/Revision Level:

Part Name/Description:

Customer Engineering Approval/Date:

Customer Quality Approval/Date:

BEST SUPPLIER COMPANYJohn Higgins 555-212-4141

ANYTOWN, USA

AX201

1AFZZZZ rev 0

FRAME WELDMENT

Supplier Contact/Phone

Supplier/Plant Location:

Stamp Plate Stamping Die2

3 Cut Tubing Cutting Saw

9 Paint Paint Line

5 Bend Tube Tubing Bend Machine

7 Weld Tubes Robotic Welder

Part Number: 1AFZZZZ Current Date: PFMEA Author:

Revision Level: N/A PFMEA Revision Date:

Part Name: FRAME WELDMENT

Process Function (Step)

Potential Failure Modes (process defects)

Potential Failure EffectsSEV

Potential Causes of FailureOCC

Current Process ControlsDET

RPN Recommended Actions

Person & Target Date

Taken Actions SEV

OCC

DET R

PN

Insufficient welding operation 6 1 3 18

Failure of chair with end customer 10 1 3 30

Incorrect or insufficient welding operation 5 4 6 120

Incorrect final dimension of chair; end

customer disatisfaction7 4 6 168

De-Burring TubeMissing or insufficient de-burring

operationIncorrect or insufficient welding operation 3

Incorrect machine set-up or

operator error6 First piece check by operator every shift 8 144

Missing or insufficient Punching

operation


operator error4

Machine sensor on punch press to detect

missing hole2 40

Incorrect Punched Hole dimension

or location

Operator error or insufficient

processing5

Machine sensors to ensure part is place

correctly in fixture2 50

Bending TubeInsufficient or excessive Bending

operationIncorrect or insufficient welding operation 6


operator error4

Hourly measurement confirmation by

operator5 120

Missing weld(s) Failure of chair with end customer 10Operator error or incorrect

machine set-up5 Visual inspection by operator 6 300

Install sendors to detect correct weld

position and size onto welding

machine

Sue C.

Due June 2006

June 2006: vision sensors installed on

weld fixture for 100% check of weld

presence and size

10 4 3 120

Weld breakabe; noise from welds;

customer disatisfaction7 4 5 140

Failure of chair with end customer 10 4 5 200see above item. Also increase

penetration check frequency

Bob J.

Due July 2006

July 2006: see sensor note above.

Penetration check frequency changed

to 1 piece every 15 minutes

10 3 3 90

Incorrect weld location Failure of chair with end customer 10Operator error or incorrect

machine set-up5

Visual inspection with template gauge; 1

piece every hour6 300 see above item

Sue C.

Due June 2006June 2006; see sensor note above 10 3 3 90

Insufficient or missing washIncorrect Powder Coat application or

longevity; end user dissatisfaction5 Incorrect machine set-up 2

Machine parameter monitors to ensure

machine is set-up and running correctly2 20

Insufficient or missing Powder CoatVisual defect; rust or end user

disatisfaction4 Incorrect machine set-up 4

Visual Inspection during unload.

Machine parameter monitors to ensure

machine is set-up and running correctly

4 64

Excessive Powder Coat Poor feeling to end user; disatisfaction 4 Incorrect machine set-up 4 Visual inpsection during un-load 5 80

Incorrect or missing Bake operationIncorrect Powder Coat application or

longevity; end user dissatisfaction5 Incorrect machine set-up 1 Visual inpsection during un-load 5 25

Color of Powder Coat on Final

AssemblyIncorrect color 4

Incorrect mixing of color for

Powder Coat operation3

Visual inspection by operator.

QA color measurement; 1 piece at start-

up

5 60

Incorrect Final Assembly

dimensions

Customer unable or has difficulty

completing the assembly of succesive

components

5Incorrect welding, or damage

during processing6

Operator gauging of part on fixtures;

once per hour.6 180

Improve handling to preserve correct

dimensions. Increase measurement

frequency.

Bob J.

Due Oct 2006

Sept 2006: Now using special

transperation carts for handling.

Gauging frequency now 2/hour

5 4 4 80

PROCESS FAILURE MODES EFFECTS ANALYSIS (PFMEA)

John Doe, 212-555-123430-Nov-06

Incorrect material

18-May-06

Material certification documents received

and reviewed with every lot of material

received from supplier

Powder Coat Assembly

Customer unable to complete assembly of

successive components5

Incorrect or insufficient weld(s)

Hourly check of dimension by operator

Visual inspection by operator.

Weld penetration analysis 2 times per

shift by QA lab

Final Inspection

Sub-supplier error; wrong material

sent


operator error


operator error

Tube Cutting

Punching Hole in Tube

Weld tubing pieces together

with plate

Incorrect cut dimension

Knoll Confidential page 1 of 1PPAP_docs_for_example#B490F.xls/PFMEA

3/29/06

2. Process Failure Modes Effects Analysis (PFMEA)A systematized technique that identifies and determines the severity, frequency and likelihood of potential failures of a manufacturing process to prioritize improvement actions. The main purpose is to aid in the prevention of defects through prioritization, although this technique also shows where detection or prevention of defects may need to be put in place.


3. Process Control PlanWritten descriptions of the system for controlling production parts at each process written by the supplier to address the critical characteristics and engineering requirements of the product. Each of the supplier’s manufacturing processes defined in the Process Flow Diagram must have its own Process Control Plan.


SAMPLE METAL COMPANY, INC.metal supply company 123 Main Street

Yourtown, PA. USA

123-456-7890

PO4256

WO77590

C MN P S Si Ni Cr Mo Cu Pb

0.15 0.6 0.035 0.035 0.044 0.11

GRADE / SIZE / PHYSICAL PROPERTIES

Customer Company, Inc.

456 Elm Street

Imaginarytown, NY USA

CR Sheet Steel, 14 Ga, ASTM-A366

Blanket Certificate for Sheets and Blanks

149,363 lbs

45,678 lbs

25-Aug-05

4000 pounds

US Steel Company Lot # QRS7341

10

Truck

178

46 Rc

0.033"

0.112"

0.001

10,000-12,000 11,459

0.0012DECARBONIZATION:

GRAIN SIZE:

F/S RATING:

SPECIFICATION REQUIREMENTS

50,000/25,000 lbs

150,000 lbs

0.125"

0.065"

45 Rc

210

YIELD STRENGTH 0.2% OFFSET:

ELONGATION IN 2 inches:

REDUCTION IN 2 inches:

HARDNESS:

PHYSICAL REQUIREMENTS MAXIMUM/MINIMUM ANALYTICAL RESULTS

TENSILE STRENGTH:

DATE SHIPPED:

WEIGHT SHIPPED:

SOURCE MILL:

SHIPPING METHOD:

PIECES/FEET:

HEAT NUMBER:

MATERIAL CERTIFICATE OF PHYSICAL AND CHEMICAL PROPERTIES

NAME AND ADDRESS: PURCHASER ORDER NUMBER:

WORK ORDER NUMBER:


4. Gage Repeatability and Reproducibility (R&R) StudyUsed to ensure that the specialty gages are capable of consistently and accurately measuring products. Gage R&R is a statistical method that accounts for the amount of variation in a measurement system from the measurement device, the people performing the measurement, the interaction between them and the error seen from the parts. A maximum of 20% is required for all critical dimensional gages.

5. Material CertificationFor certain commodity raw materials, a detailed sheet is supplied by the raw material vendor to a supplier, showing the chemical and physical properties of a particular production lot or run of raw material, which acts as a confirmation that the correct material will be used in the production of parts for Knoll. This document will look different depending on the commodity, the sub-supplier and other factors but should contain the same type of information. The supplier needs to receive this document with every order of raw material from its vendor, and keep it on file, for audit or inspection by Knoll at any time.


Gage R & R Report- Input SheetNumber of Trials: 3

Number of Operators: 3

Number of Parts Measured: 10

Operator A: Larry McBarry Enter Upper Spec Limit: 1.45

Operator B: Sue Z. Que Enter Lower Spec Limit: 0

Operator C: Jeff Cross

Operator / PART #

Trial # 1 2 3 4 5 6 7 8 9 10 Avg

1 A 1 0.960 0.090 0.240 0.500 1.110 0.360 0.580 1.030 0.130 0.220 0.522

2 2 0.850 0.090 0.270 0.540 1.050 0.370 0.520 1.000 0.130 0.240 0.506

3 3 1.750 0.480 0.570 1.660 2.080 0.770 1.080 1.970 0.300 0.560 1.122

4 Average 1.187 0.220 0.360 0.900 1.413 0.500 0.727 1.333 0.187 0.340 0.717

5 Range 0.900 0.390 0.330 1.160 1.030 0.410 0.560 0.970 0.170 0.340 0.626

6 B 1.610 0.400 0.480 1.570 2.070 0.700 1.080 1.930 0.320 0.570 1.073

7 1.750 0.480 0.570 1.660 2.080 0.770 1.080 1.970 0.300 0.560 1.122

8 0.850 0.090 0.270 0.540 1.050 0.370 0.520 1.000 0.130 0.240 0.506

9 Average 1.403 0.323 0.440 1.257 1.733 0.613 0.893 1.633 0.250 0.457 0.900

10 Range 0.900 0.390 0.300 1.120 1.030 0.400 0.560 0.970 0.190 0.330 0.619

11 C 1.610 0.400 0.480 1.570 2.070 0.700 1.080 1.930 0.320 0.570 1.073

12 0.850 0.090 0.270 0.540 1.050 0.370 0.520 1.000 0.130 0.240 0.506

13 1.750 0.480 0.570 1.660 2.080 0.770 1.080 1.970 0.300 0.560 1.122

14 Average 1.403 0.323 0.440 1.257 1.733 0.613 0.893 1.633 0.250 0.457 0.900

15 Range 0.900 0.390 0.300 1.120 1.030 0.400 0.560 0.970 0.190 0.330 0.619

16 PartAvg

0.9 0.39 0.31 1.13333333 1.03 0.40333333 0.56 0.97 0.18333333 0.333333330.621

17 0.626 0.619 0.619 3 0.621

18 0.900 0.717 0.184

19 0.621 2.58 1.603

20 0.621 0 0

( )x p

Xa=

Ra=

Xb=

Xc=

Rc=

R =[Ra

Rb

Rc

OF OPERATO RS = ] == + = + = ] / [#

[Max x = - Min x = ] = xdiff

[R = x D UCL4 R= =]

Rb=

[R = x D LCL3 R= =]

xdiff

=

LCLR=

UCLR=

Rp=

Part No. and Name: FRAME WELDMENT Gage Name: LOCATOR GAGE Date: 5/6/89

Characteristics CRITICAL DIM.S Gage No: 12XC34 Performed by:

Specification 0 to 1.45 Gage Type: FIXTURE Randal Posser

From Data Sheet: 0.0455 1.0975 0.0455

Measurement Unit Analysis % Process Variation

Repeatability - Equipment Variation (EV)

=100[ 0.20748 / 1.45 ]

= 0.0455 X 4.56

= 14.309

= 0.20748

Reproducibility - Appraiser Variation (AV)

= [( 1.0975 X 3.65 )2-( 0.20752/( 10 X 2 ))] =100[ 4.005606 / 1.45 ]

= 4.005606 = 276.249

Repeatability & Reproducibility (R&R)

=100[ 4.010976 / 1.45 ]

= ( 0.207482+ 4.005606

2)

= 276.619

= 4.010976

Part Variation (PV)

=100[ 0.07371 / 1.45 ]

= 0.0455 X 1.62

= 5.083

= 0.07371

Tolerance Width (TW) ACCEPTABILITY CRITERIA

* Under 10% error - Gage system O.K.

* 10% to 30% error - May be acceptable

= 1.45 - 0 based on the importance of the

application, cost of the gage, cost of

= 1.45 repair, etc..

* Over 30% - Gage needs improvement.

Make every effort to identify problems

and have them corrected.

Gage R & R Report- Tolerance Width

EV R x K=1

AV X xK EV nrdiff= [( ) ( / ( ))]2

2 2

R R EV AV& ( ) ( )= +2 2

PV R x Kp

=3

TW Upper Spec Limit Lower Spec Limit=

% & [ & / ]R R R R TW= 100

% [ / ]EV EV TW= 100

% [ / ]AV AV TW= 100

% [ / ]PV PV TW= 100

xdiff

= Rp =R =

Part No. and Name: FRAME WELDMENT Gage Name: LOCATOR GAGE Date: 5/6/89

Characteristics: CRITICAL DIM.S Gage No: 12XC34 Performed by:

Specification: 0 to 1.45 Gage Type: FIXTURE Randall Posser

From Data Sheet: 0.0455 1.0975 0.0455

Measurement Unit Analysis % Process Variation

Repeatability - Equipment Variation (EV)

=100[ 0.20748 / 4.0116534 ]

= 0.0455 X 4.56

= 5.172

= 0.20748

Reproducibility - Appraiser Variation (AV)

= [( 1.0975 X 3.65 )2-( 0.20752/( 10 X 2 ))] =100[ 4.0056063 / 4.0116534 ]

= 4.0056063 = 99.849

Repeatability & Reproducibility (R&R)

=100[ 4.0109762 / 4.0116534 ]

= ( 0.207482+ 4.0056063

2)

= 99.983

= 4.0109762

Part Variation (PV)

=100[ 0.07371 / 4.0116534 ]

= 0.0455 X 1.62

= 1.837

= 0.07371

Total Variation (TV) ACCEPTABILITY CRITERIA

* Under 10% error - Gage system O.K.

* 10% to 30% error - May be acceptable

= ( 4.01097622+ 0.07371

2) based on the importance of the

application, cost of the gage, cost of

= 4.0116534 repair, etc..

* Over 30% - Gage needs improvement.

Make every effort to identify problems

and have them corrected.

Gage R & R Report- Total Variation

EV R x K=1

AV X xK EV nrdiff= [( ) ( / ( ))]2

2 2

R R EV AV& ( ) ( )= +2 2

PV R x Kp

=3

TV R R PV= +( & )2 2

% & [ & / ]R R R R TV= 100

% [ / ]EV EV TV= 100

% [ / ]AV AV TV= 100

% [ / ]PV PV TV= 100

xdiff

= Rp =R =



6. Appearance And Color Approval Appearance Approval Report

A supplier-completed document listing quantified measurements of color, texture, and other visual specifications using applicable test equipment and techniques. Color Approval

In office furniture, as well as with any home furnishing, the color of materials, whether wood, plastic, metal, textile or paint, is a primary concern to designers, architects and customers. The potential for a customer to order additional products at a later time requires that Knoll’s products not change color over time, to ensure matching of the initial purchase.

Knoll has put a great amount of effort into the standardization of its color program. A large investment in color measuring and monitoring equipment and technical training of associates has ensured that Knoll has reduced warranty costs relating to color issues.

Suppliers are required to formulate finishes and materials to Knoll’s master samples, and to submit color samples for approval just as they would any first article submission.

“Grand Masters” become the measurement standard for Production Color Masters. All Grand Master numerical color data is stored in Knoll’s spectrophotometer. Samples, when submitted for Production Master approval, are compared both numerically and visually to the “Grand Master”. Approved matching Production Masters will be maintained at the supplier and at Knoll. Numerical data is maintained in the spectrophotometer for future comparisons.

PART NUMBER 1AFZZZZ DATE

PART NAME OTHER

SUPPLIER NAME MANUFACTURING LOCATION

REASON FOR SUBMISSION INITIAL SUBMISSION SPECIAL SAMPLE RE-SUBMISSION

PRE TEXTURE FIRST PRODUCTION

SUPPLIER SOURCING AND TEXTURE INFORMATION PRE-TEXTURE EVALUATION CUSTOMER REPRESENTATIVE

SIGNATURE AND DATE

CORRECT AND PROCEED

CORRECT AND RESUBMIT

APPROVED TO TEXTURE

COLOR MASTER

SUFFIX DL* Da* Db* Cielab DATE RED GRN BLU LIGHT DARK GRAY CLEAN HEIGH LOW SUFFIX

BLK 45 0 65 0.55 4/1/06 43 143 12 0.4 1 6.2 0 0.3 -.9 blk

COMMENTS

SUPPLIER SIGNATURE PHONE DATE CUSTOMER SIGNATURE

REV.DRAWING NUMBER

BUYER

4/1/06123-456-7890 Dr. Fred Wilson

N/A

APPEARANCE APPROVAL REPORT

VALUE

AX201 0

TRISTAMULUS DATA MASTER

SOURCE YEL

HUEMASTER

NUMBER

FRAME WELD.

Best Supplier Co.

APPEARANCE EVALUATION

DE*

Elizabeth G

Anytown, USA

CHROMA

Bill E. Checker

Part was painted per QAR-056 in PAINT-O-MATIC paint booth.Baked at 350 degrees.Color was mixed per specification. Bill E. Checker

4/10/06

COLOR EVALUATION

0.3 SUPPLIER

1AFZZZZ 5-Apr-06

n/a


Sprite™ Stacking Chairs




7. 30 Piece Measurement Capability Study A statistical process performed on all critical dimensions of a part whereby an appropriately sized population of parts (minimum 30 pieces) are measured to statistically determine the total range of inherent variation and stability of the manufacturing process.

8. Part Submission WarrantA process performed on all parts or parts that have been revised for dimensional changes, new or revised tooling, manufacturing processes or tooling that has been relocated, and any product produced by an alternate or new process method. This process, including the First Article Inspection Report (FAIR) should be followed and submitted to Knoll if there are any of these changes with Knoll’s sub-suppliers as well as its tier one suppliers.

DATA COMPILED BY: 3/12/06

DATA COLLECTION BY: John Doe

PART NAME: FRAME WELDMENT PRODUCT AREA: Welding Area

PART # 1AFZZZZ

n 1 2 3 4 5 6 7

1 20.658 19.014 19.917 159.554 2.125 66.297 32.491

2 20.628 19.168 19.903 155.101 1.573 66.154 33.273

3 20.729 19.025 19.814 160.329 1.999 67.851 32.520

4 20.661 19.204 19.866 158.668 1.972 66.814 32.953

5 20.698 19.131 19.797 158.153 2.146 67.386 32.366

6 20.729 19.196 19.720 155.739 1.872 67.901 32.395

7 20.634 19.220 19.695 155.729 2.169 66.031 32.567

8 20.663 19.114 19.816 155.964 1.629 67.045 33.146

9 20.620 19.202 19.699 156.876 2.213 67.130 33.094

10 20.692 19.158 19.797 156.625 1.742 67.181 33.301

11 20.638 19.104 19.713 159.986 1.525 66.690 33.104

12 20.700 19.116 19.903 158.005 1.932 66.716 32.920

13 20.661 19.138 19.887 158.714 1.894 66.443 32.623

14 20.674 19.113 19.833 159.314 1.892 67.131 32.512

15 20.697 19.119 19.887 156.810 1.513 67.506 32.419

16 20.687 19.034 19.915 156.240 2.083 66.146 33.204

17 20.718 19.107 19.820 158.674 2.206 66.811 32.722

18 20.662 19.177 19.941 160.086 1.645 67.157 33.101

19 20.687 19.145 19.735 156.415 2.216 66.440 32.478

20 20.718 19.163 19.718 155.118 1.540 67.354 33.029

21 20.665 19.071 19.847 157.644 1.522 66.389 32.865

22 20.657 19.139 19.698 159.715 1.803 67.805 33.328

23 20.629 19.159 19.682 158.017 2.110 67.259 32.704

24 20.667 19.042 19.756 156.222 2.249 67.325 32.911

25 20.711 19.150 19.875 155.873 1.668 67.866 32.729

26 20.690 19.122 19.784 156.709 2.227 66.037 32.705

27 20.715 19.139 19.782 155.281 1.961 67.368 32.546

28 20.726 19.172 19.944 155.547 1.772 67.110 32.427

29 20.685 19.125 19.814 156.628 1.666 66.007 32.660

30 20.674 19.246 19.775 159.699 2.210 66.385 32.757

Mean 20.679 19.134 19.811 157.448 1.902 66.925 32.795

Std. Dev. 0.032 0.056 0.081 1.682 0.254 0.591 0.300

Max. 20.73 19.246 19.944 160.329 2.249 67.901 33.328

Min. 20.62 19.014 19.682 155.101 1.513 66.007 32.366

Cp 1.410 1.664 1.754 2.060 1.373 1.511 1.350

Cpk 1.342 1.446 1.336 1.822 1.333 1.400 1.310

USL 20.730 19.250 19.960 160.700 2.300 68.000 33.350

LSL 20.620 19.010 19.640 154.600 1.500 66.000 32.350

USL-Mean 0.051 0.116 0.149 3.252 0.398 1.075 0.555

Mean-LSL 0.059 0.124 0.171 2.848 0.402 0.925 0.445

Judgement OK OK OK OK OK OK OK

30 PIECE CAPABILITY STUDY

Part Name Part Number

Safety and/or

Government Regulation Yes No Engineering Drawing Change Level Dated

Additional Engineering Changes Dated N/A

Shown on Drawing No. Purchase Order No. K345-05 Weight (kg)

Checking Aid No. G-54685-A Engineering Change Level ECN-875-06 Dated

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Dimensional Materials/Functional AppearanceSupplier Name & Supplier Code

Customer Name/Division Knoll, Inc.- EG

Street Address Buyer/Buyer Code Terry Matten

Application Frame Weldment for ChairCity Zip

NOTE: Does this part contain any restricted or reportable substances. No

Are plastic parts identified with appropriate ISO marking codes. No

REASON FOR SUBMISSION

Initial Submission Change to Optional Construction or Material

Engineering Change(s) Sub-Supplier or Material Source Change

Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing

Correction of Discrepancy Parts Produced at Additional Location

Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check One)

Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.

Warrant with product samples and limited supporting data submitted to customer.

Warrant with product samples and complete supporting data submitted to customer.

Warrant and other requirements as defined by customer.

Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

SUBMISSION RESULTS

The results for dimensional measurements material and functional tests appearance criteria statistical process package

These results meet all drawing and specification requirements: Yes No (If "NO" - Explanation Required)

Mold / Cavity / Production Process

DECLARATION

I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable

Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were

produced at the production rate of / 8 hours. I have noted any deviations from this declaration below.

Explanation/Comments:

Print Name Title Phone No. FAX No.

Supplier Authorized Signature Date

Part Warrant Disposition: Approved Rejected Part Functional Approval: Approved

Other Waived

Customer Name Customer Signature Bill E. Checker Date

The original copy of this document shall remain at the suppliers location Optional: customer tracking

while the part is active (see Glossary). number: #

A copy shall be submitted along with the part samples to the Customers Quality department.

Part Submission Warrant

3/8/06

123 Main St.

Best Supplier Co.

1AFZZZZ

11/5/04

0.34

2002

July

Level 5 -

Dr. Fred Wilson

Knoll, Inc.

Cutting, de-burr, punch, weld, paint

300

QA Manager

Level 3 -

Level 4 -

State

Level 1 -

Level 2 -

123-456-7890 123-555-9991

5/18/06

Dr. Fred Wilson 4/6/06

FOR KNOLL USE ONLY (IF APPLICABLE)

Anytown, PA 12345

Yes

Yes

FRAME WELDMENT

None

N/A

Cp = the capability of the process Cpk = the deviation between the target and the mean USL = the upper specification limit LSL = the lower specification limit σ = the standard deviation of the sample population X = the mean of the sample population

Cp = (USL - LSL)

6σ

Cpk = min[(USL - X) ,

3σ(X - LSL)

3σ]



9. First Article Inspection Report (FAIR) Suppliers are required to submit three representative samples from production materials, tooling, processes, gages, operators and environment and document findings on all characteristics and dimensions specified by Knoll. The FAIR submitted to Knoll by the supplier must include the following items:

• A marked drawing with all dimensions and specifications identified by ballooned numbers.

• One sample part from the submitted samples must have a full dimensional check, which includes all dimensions and specifications listed on the drawing.

• The remaining required two FAIR sample parts need only the major and critical dimensions and specifications checked as indicated by the nomenclature on the drawing.

• The dimensional data submitted to Knoll must include:

– The nominal dimension as it corresponds to the ballooned numbers on the drawing – The upper and lower tolerances for all dimensions – The actual part measurement – The out-of-tolerance amount indicated with + or – as applicable

• The report should also indicate the methods of measurement and/or testing for each of the specifications checked.

• Any aesthetic or dimensional concerns should be noted.

• Any differences between the First Article samples submitted, and the regular production (methods, tooling, equipment, material, adjustments, etc.) should be indicated.

• For parts with a color finish, the CIE-LAB (International Commission on Illumination, Light/Dark, Red/Green, Blue/Yellow) measurement is required for all colors specified. Actual parts should be measured. The data should indicate illuminate, angle of observance, and color formula used (i.e. CIE-LAB, FMC II).

• The FAIR package should also include a Process Control Plan for all new parts and a revised Process Control Plan when the revision alters the existing Process Control Plan.

• Material Certification data is required, where applicable, to ensure conformity with the material requirements indicated by Knoll, to ensure that the specifications are being met.

• Environmental data as applicable, including product recycled content (both post-consumer and post-industrial), Material Safety Data Sheets, and product wood certification.

Upon completion of all the requirements of the FAIR, the supplier will send three sample parts and documents to its Knoll Quality Assurance representative for review. Upon approval, Knoll will provide a signed document indicating approval to proceed with production.


SUPPLIER RESPONSIBILITY

Phone

Fax

PART INFORMATION

Part Name

Rev. Level n/a Dated 11/5/04

New Part New Supplier Process Change

New Tooling Revised part

Samples made on production tooling? Yes No

Parts checked to drawing number Rev Level n/a

34-450

Only acceptable samples should be shipped to Knoll for review. Ship parts to Knoll purchasing:

East Greenville Muskegon

Grand Rapids Toronto

We hereby certify that the inspection results are correct and that our samples meet all specifications.

Signature of Responsible Official

Title Date 4/28/06

KNOLL USE ONLY

APPROVED REJECTED CONDITIONAL APPROVAL

(Indicate required action) (Indicate required action)

COMMENTS:

Signature Title Date 5/1/06

Form 1535422 Rev 01 3/30/01

Copies to: QA Supplier Purchasing Engineering

Bill E. Checker Inspector

30 Additional samples requested, including Cp/Cpk measurements on all critical dimensions. Due 5/15/06

Fred Wilson

QA Manager

Die Model number Semi finished part Finished part

Drawing Number 1AFZZZZ

Reason for Sample

# of pieces run

Part Number 1AFZZZZ Frame Weldment

Address 123 Main St. 555-121-9111

Anytown, USA

FIRST ARTICLE INSPECTION REPORT

Company Name Best Supplier Company, Inc. 123-456-7890

DEVIATION COVER SHEET for FAIR DIMENSIONAL MEASUREMENTS

FIRST ARTICLE REPORT # 5649-877 SUBMISSION #

ADDRESSEE

PART NO MATERIAL

DESCRIPTION

VENDER PURCHASER

P.O.NO. LINE Assembly 6B NEW REV

DRAWING NO. REV. n/a REV. DATE

NEXT ASSY. DATE REC. OTHER

The following issues have been found to deviate from Knoll specifications. Each issue must be addressed to satisfy

the product specification.

INSPECTED BY: DATE 5/30/06 SUPPLIER

ITEM NO. SPEC CHANGE REJECT CORRECTION

-----------

14 + 0.05 -----------

-----------

15 - 0.03 -----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

-----------

KNOLL USE ONLY

TOOLING PAYMENT APPROVAL YES NO

DIMENSIONAL FINAL DESIGN PRODUCTION

DISPOSITION:

ACCEPT ENGINEERING DATE

REJECT QUALITY DATE

CONDITION OF ACCEPTANCE

COLOR INFORMATION n/a APPROVAL REJECTION

ACCEPTANCE WITH SPEC. CHANGES REQUIRES AN ECN FOR ADDRESSING EFFECTED DEVIATIONS BE FORWARDED

ALONG WITH A SIGNED-OFF REPORT TO THE FIRST ARTICLE INSPECTION QUALITY ENGINEER.

ITEMS DEEMED AS REJECTED MUST BE RESUBMITTED AND APPROVED(VIA THE FIRST ARTICLE INSPECTION PROCEDURE)

AFTER TOOLING OR PROCESS MODIFICATIONS ARE COMPLETED. EG-QA-1017

Best Supplier Co.

K459-9876

Knoll, Inc.

14G-12

1AFZZZZ

Frame Weldment

--------

--------

--------

--------

--------

Seating Assembly Unit 165-UJ

--------

--------

--------

--------

--------

--------

------

------

--------

--------

--------

--------

--------

--------

--------

--------

------

------

------

------

------

------

------

------

------

------

------

------

Supplier has installed corrective action; replace punch die & proven by new Cp/Cpk

John Q. Knoll 6/2/06

6/1/06

Dimensional Report

DEVIATION

5/21/06

------

------

------

------

------

Bill E. Checker

CHARACTERISTIC

Outside diameter of punched hold

Inside diameter of punched hole

Joe D.

n/a1AFZZZZ

Side Chair

CATEGORY

F.A.I.R. DIMENSIONAL REPORT1 piece ALL dimensions, 2 pieces critical dimensions

Date:

Drawing#: 1AFZZZZ Rev.: n/a ECN# 564-563254 Effectivity Date: 3/28/06

Description: Frame Weldment Manufacture date: 4/30/06

Q.A. Log#: 2134-4 Part#: Layout By: John Higgins

Dim. Critical Nom. Tolerance Part 1 Out Part 2 Out Part 3 Out Avg Max/Out Rnge

1 20.67 0.06 0.05 20.674 -.046 20.718 -.002 20.686 -.034 20.693 -.046 .044

2 8.27 0.03 -0.03 8.300 8.300

3 0.25 0.003 0.003 .253 .000 0.253 .000

4 3.0 0.10 -0.10 3.100 3.100

5 13.331 0.15 -0.15 13.481 13.481

6 19.13 0.03 -0.03 19.160 19.160

7 21.55 0.03 -0.05 21.587 .007 21.587 .007

8 12.44 3.00 -3.00 15.440 15.440

9 19.13 0.12 -0.12 19.250 19.250 19.250 19.250

10 19.80 0.16 -0.16 19.960 19.960 19.960 19.960

11 12.44 0.00 -0.08 12.483 .042 12.483 .042

12 18.66 0.03 -0.03 18.690 18.690

13 11.44 0.03 -0.03 11.470 11.470

Q.A. Log#: 2134-4 Part#: 1AFZZZZ Layout By: John Higgins

1AFZZZZ

5/18/06




10. Production Part Dimensional ReportA three-piece measurement analysis submitted with every preproduction sample, consisting of a measurement of all dimensions on one part and all critical dimensions, as defined on the drawing of two other parts. If needed, this document will also accompany production shipments and show data for critical dimensions for three parts. It confirms that the parts shipped meet all other agreed-upon specifications to ensure that Knoll does not receive discrepant material. Specific requirements concerning this document will be evaluated on a case-by-case basis.

SUPPLIER INFORMATIONSUPPLIER NAME: CONTACT NAME:

SUPPLIER ADDRESS: TELEPHONE:

EMAIL:

KNOLL PURCHASE ORDER INFORMATION

KNOLL PURCHASE ORDER NUMBER: K34653-0 KNOLL PART NUMBER:

DUE DATE AT KNOLL: KNOLL REVISION LEVEL:

ORDER QTY:

PART INFORMATION

PART NUMBER: PART NAME:

DRAWING NUMBER: REVISION LEVEL:

DRAWING DATE:

PRODUCTION INFORMATION

SHIPPING QUANTITY:

PRODUCTION DATE:

PACKAGING TYPE:

PACKAGE WEIGHT (kg): 10 kg

DIMENSIONAL INFORMATION (3 pieces required)

DRAWING NUMBER: INSPECTOR NAME:

DRAWING REVISION LEVEL:

Critical Dimension Description Specification

LowerTolerance

Limit

UpperTolerance

Limit

Measurement Tool

Piece #1 measurement



SupplierJudgment(OK or NG)

KnollJudgment(OK or NG)

Width- Top View 20.67 -0.05 +0.06 Calipers 20.64 20.62 20.68 OK

Inner Width- Front View 19.13 -0.12 +0.12 Calipers 19.03 19.22 19.18 OK

Outer Width- Front View 19.80 -0.16 +0.16 Calipers 19.72 19.88 10.84 OK

KNOLL FINAL REVIEW

KNOLL INSPECTOR: KNOLL REVIEW DATE:

KNOLL APPROVE/REJECT: KNOLL COMMENTS:

10/1/06

Fred Jones

[email protected]

N/A

FRAME WELDMENT

n/a

1AFZZZZ

Best Supplier Company

Anytown USA

10/1/06

EXPECTED DATE TO LEAVESUPPLIER:

N/A

Peter C.

11/30/06

COMPLETED SHEET & MATERIAL CERTIFICATION SHOULD BE EMAILED OR FAXED TO THE KNOLL PURCHASE ORDER AUTHOR

1AFZZZZ

N/A

Approved

EXPECTED DUE DATE TO KNOLL:

10,000

11/30/06

Bill E. Checker

10,000

Returnable Carton

1AFZZZZ

1AFZZZZ

11/1/06

11/5/04

Chadwick™ Chair


Ownership of Quality 19

Knoll relies on the principle of Ownership of Quality.

This principle is applied internally at Knoll as well as to its suppliers. The production and delivery of quality products are the responsibility of everyone in the supply chain.

When new suppliers or products are introduced at Knoll, or when component quality concerns are noted, inspections will be conducted until acceptable quality levels are assured. Characteristics subject to inspection may include dimensions, material properties, testing performance, and color/finish/feel properties. Any inspections needed are required to be performed prior to Knoll’s warehouse receipt of material from the supplier and are to be conducted in accordance with the quality specifications agreed upon with Knoll.

In the event Knoll is supplied with product that does not meet its specifications or for which a specification does not exist; discrepant material in the work environment can lead to production slowdowns, costly rework time, no-build situations or, at worst case, a dissatisfied end customer. Knoll requires that suppliers notify it if any of the following conditions exist or arise:

• The supplier has been supplying product under unauthorized specifications, written notes, verbal instructions, etc.

• The supplier has been supplying product known to differ from the part drawing or specifications.

• The supplier discovers, during production, that material produced is out of Knoll specifications.

The type and magnitude of the discrepancy will determine the action taken by Knoll. Rejections can trigger:

• Discrepant Material documentation and needed supplier actions

• Product moved from a “ship-to-stock” status to an “inspection-upon-receipt” mode.

• Issuance of a Supplier Corrective Action Request (SCAR)

• Supplier on-site sorting of product at Knoll

• Supplier replacement of the parts, with expedited freight as needed.

• On-site audits, by Knoll quality and/or purchasing personnel, of the supplier’s facility.

• Warranty claims

• Negative impact on Supplier Rating, which could affect the opportunity for receiving business from Knoll

• Requirement of the supplier to pay for the total cost incurred by Knoll caused by the discrepancy

Suppliers are expected to be responsive and timely with their corrections to any issues that may arise and to take ownership of quality for their products.

Ownership Of Quality

AutoStrada™ Collaborative Planning


20 Discrepant Material Procedure

Any non-conforming purchased product that does not meet the agreed-upon specifications will be documented by Knoll as a Rejection Notice (RN) with a copy being sent to the supplier requiring that they decide on the disposition of the material. When an RN is created, a copy is sent to the supplier to inform it that there will be an upcoming debit on future payments.

Disposition of non-conforming purchased product can be worked out with the appropriate Knoll contact for each occurrence. The supplier may choose to allow Knoll to directly scrap the parts, or the supplier may request that Knoll return the defective parts, at the supplier’s expense, to allow a thorough root-cause investigation and permanent corrective actions to prevent any future recurrence of the problem.

Discrepant Material Procedure

The supplier is expected to work with the appropriate Knoll representative to ensure that the specific quality problem does not recur in the future and to complete any needed quality paperwork, such as a Supplier Corrective Action Request. Any countermeasures implemented may be audited during a future Knoll visit. Knoll’s corporate Supplier Quality department may also become involved, as needed.

For the rejected parts, Knoll will debit the supplier for the cost of the products, and any incoming freight charges, as well as a potential processing fee for each rejection notice written. Details of applicable charges will be worked out by the Knoll materials group and the supplier on a case-by-case basis.

If replacement parts are required to fill a gap in the supply chain due to the rejection, Knoll expects its supplier to take any and all necessary steps to produce new product that meets all specifications and to deliver the product so that it arrives at Knoll in a timely manner to satisfy Knoll’s manufacturing requirements.

Calibre® and Series 2™ Storage


Supplier Corrective Action Request 21

The Knoll Supplier Corrective Action Request (SCAR) form is used in any of the following situations:

• Material is not rejectable, but the level of quality is becoming a concern

• Clarification of a major rejection

• An addendum to a First Article Inspection Report (FAIR)

• Additional information is needed to determine appropriate receiving inspection levels

• When non-conforming supplier material is found at Knoll or a Knoll customer

Knoll’s suppliers are required to answer all inquiries by the due date indicated on the SCAR form. If the supplier misses the due date without contacting Knoll Quality Assurance, Knoll Purchasing may request the supplier to visit Knoll to clarify the quality issue and corrective actions.

The completed form should be sent to the Quality Assurance Department.

Supplier Corrective Action Request To:

Phone:SCAR#

MAT'L STOP or

Receiving Area Manuf. Floor

CAUSE

NEW SHIP DATE

9/27/06

Ref. KG-QA-1003 Supplier Corrective Action-11/03 (Fig. 1)

Frame weldments were received with scratches on black finish due to insufficient & incorrect packaging method

COMPLETED WHITE-QUALITY

Correct packaging was not available; Operators were told to use interim packaging instead

Operation Instructions were modified, photos added, and operators/suprevisors/engineers were trained that correct packaging must be used in all

circumstances to prevent reoccurances

Fork Lift operator instructions have been added, and Lift Operators have been trained that they must not move or accept product packaged in anything

but the correct packaging. Photos have been added to instructions.

Return to attention of the Quality Assurance Dept. of Knoll, Inc. per checked address above. QA VERIFY

SIGNATURE

Dr. Fred Wilson

GOLD - QUALITY

COMPLETED YELLOW - SUPPLIER COMPLETED GREEN - PURCHASING

PINK - PURCHASING

DATE

9/28/06

SERIAL NO.

54-867

LOT NO.

Q48-87

CORRECTIVE ACTION EFFECTIVITY

9/27/06

NAME AND TITLE OF SUPPLIER'S REP.

Dr. Fred Wilson

PREVENTIVE MEASURE

CORRECTIVE ACTION TAKEN

You are hereby requested to investigate this problem, take appropriate corrective action and provide a plan to prevent recurrence of similar

ATTENTION -- SUPPLIER QA/QC MANAGER: Complete the entire Section 4 and Return by Due Date

discrepany(ies). Your response must be received by . . . . . . . . 10/1/06

TITLENAME

Terry Matten Materials Manager

DATE

9/13/06

DATE

9/15/06

REJECTION NOTICE NO.

5459-986-73

Fax No.and/orEmail

[email protected]

PART NO.PART NAME

1AFZZZZ rev n/a

Section 1

LOT ID

435-596-876

DISPOSITION

Return to supplier; per their request

KN326-97865

ENG. CHANGE LEVEL

DISCREPANT QUANTITY

353

Section 2

Section 3

Section 4

THE MATERIAL IDENTIFIED HEREON HAS BEEN REJECTED FOR THE FOLLOWING DISCREPANCY(IES)

QualityAssurance

Purchasing

NAME

Joe Q. Aulity

TITLE

QA Manager

Frame Weldment

SUPPLIER CORRECTIVE ACTION REQUEST

Best Supplier Company123 Main St.Anytown, USA

123-456-78904567-053465

2800 EstesP.O.Box 209Muskegon, MI 49443-0209

1000 Arrow RoadWeston (Toronto), ON M9M 2Y7Canada

4300 36th Street, SEP.O.Box 8829Grand Rapids, MI 49518-8829

1235 Water StreetP.O.Box 157East Greenville, PA 18041


Supplier Rating

22 Supplier Rating

Knoll suppliers are rated for their delivery and the quality accuracy of their supply of production parts. All measured components – Quality, On-Time Delivery, Cost and paperwork accuracy are combined for a composite score and are reported regularly to the Knoll Purchasing department for evaluation.

The Supplier Rating value is a strong component in supplier selection decision for the awarding of new Knoll business as well as retaining any Knoll supply relationship.

It is also the cornerstone of Knoll’s Quality Recognition Program, where positive ratings can allow suppliers to have a preferred status for new business quoting and possible awards.

Suppliers not meeting the agreed-upon standards will be considered for elimination if they cannot implement acceptable corrective actions to problems encountered.

Knoll reserves the right to visit a supplier’s manufacturing facility or escort a customer to a supplier to ensure the quality of purchased materials.

Dividends® Office System


Working Together For Continuous Improvement 23

Working Together For Continuous Improvement

Knoll utilizes a number of continuous improvement tools such as Kaizen events, Six Sigma analysis, Value Stream Mapping, set-up time reduction, 5-S programs, Mistake Proofing, Lean principles and Total Productive Maintenance. Knoll’s activities involve all of its associates and supply-chain partners in evaluating and improving quality, shortening

Delivery leadtimes, improving Safety in all areas of the supply chain, and reducing Costs by eliminating waste in its many forms. These continuous improvement activities within the complete supply chain will improve Knoll’s competitiveness in the ever-growing global market and ensure future opportunities for its suppliers and associates.


The following checklist is intended to aid the supplier to ensure compliance with Knoll’s Supplier Quality Guidelines outlined in this brochure.

Initial Supplier Establishment and Preproduction Activities

Supplier Self Assessment Survey completed and submitted to Knoll

Knoll visit and audit of supplier’s manufacturing facility

Supplier understands all of Knoll’s requirements

• Engineering specifications

• Environmental requirements

• Testing requirements

• Quality specifications and Quality Assurance Requirements

• PPAP requirements

• Color and texture requirements

• Packaging specifications

• Quoting requirements

Production Part Approval Process

Design records (part drawings, industry specifications, CAD/CAM files, engineering change documents, etc).

Process Flow Chart

Development of Knoll Quality Assurance Requirements (QAR)

Process Failure Modes Effects Analysis (PFMEA)

Process Control Plans

Drawings and/or descriptions of specialty gaging or measurement equipment to be used for production parts

Gage Repeatability and Reproducibility study for all specialty gages

Material Certifications

Design engineering approval via Knoll’s FAIR and Functional Approval

Successful test results, including material certification with structural testing when required

Process Capability Studies on at least 30 pieces for all critical dimensions

Appearance approval report and color approval

Environmental information of recycled content, air quality testing data and MSDS

Part Submission Warrant

Dimensional results via Knoll’s First Article Inspection Report (FAIR)

• 1 piece ALL dimensions

• 2 pieces all CRITICAL dimensions

Knoll approval to begin producing production parts

Production Parts Supply

Production Part Dimensional Report when applicable

Knoll label requirements

Knoll part number and revision level, quantity in box, Knoll purchase order number, and supplier’s manufacture date or lot code

Packing lists and invoices contain all of the required Knoll information

Supplier is utilizing all items listed in PPAP documentation and will consistently supply the highest quality parts to Knoll on time

On-going continuous improvement of Quality, Cost and Delivery

Supplier Checklist

Ricchio® Chair


Knoll, Inc. (Headquarters) 76 9th Avenue, Floor 11 New York, NY 10011 USA 212 343-4000

Knoll, Inc. 1235 Water St. East Greenville, PA 18041 USA 215 679-7991

Knoll, Inc. 4300 36th St. SE Grand Rapids, MI 49512 USA 616 949-1051

Knoll, Inc. 2800 Estes St. Muskegon, MI 49441 USA 231 755-2270

Knoll North American Corp. 1000 Arrow Rd. Weston, Ontario M9M 2Y7 Canada 416 741-5453

Knoll International SpA Via San Colombano, 67 26813 Graffignana, Iodi Italy 0039 0371 20691

Knoll Contact Information

Knoll Contact Information 25

Knoll Contact Information

Knoll, Inc. (Headquarters)) 76 9th Avenue, Floor 11 New York, NY 10011 USA 212 343-4000

Knoll, Inc. 1235 Water St. East Greenville, PA 18041 USA 215 679-7991

Knoll, Inc. 4300 36th St. SE Grand Rapids, MI 49512 USA 616 949-1051

Knoll, Inc. 2800 Estes St. Muskegon, MI 49441 USA 231 755-2270

Knoll North American Corp. 1000 Arrow Rd. Weston, Ontario M9M 2Y7 Canada 416 741-5453

Knoll International SpA Via San Colombano, 67 26813 Graffignana, Iodi Italy 0039 0371 20691

Knoll Contact InformationReturn to Table of Contents

Knoll Contact Information 25

knoll.com PUR-0033 rev1 © 2006 Knoll, Inc. All rights reserved.

Supplier Quality Handbook -

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