Beruflich Dokumente
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December 2012
NEWSLETTER
with a few other members attended a meeting in September in Louisville. I do want to thank all of those members who were able to attend and their participation in developing the 2013 Strategic Business Plan and Budget. Jenny Persfull did a wonderful job in making arrangements and working with the attendees to make the meeting a positive experience. Greg Gay stepped to the plate and was instrumental in development of the budget to support the plan. Shirl Furger, ASQ Headquarters, provided us tremendous support and assistance in ensuring the plan was in alignment with the ASQs overall business plan and objectives. Molly Brown as Nominating Committee chair along with her sub-committee members - Jenny Persfull and Navin Dedhia - were instrumental in creating our new leadership team. I want to congratulate my fellow elected team members Joe Wesling, Incoming Chair-elect; Jackie Schaefer, Treasurer; and Jim Spichiger, Secretary. Jim, during the past year, has worn many different hats to support the division. He served as our Membership Chair but also was acting secretary, Scholarship Chair and Inspector of the Year Chair. Greg Gay has held numerous positions in our division and his most recent position was Treasurer. [Continued on Page 2..] .
IN THIS ISSUE
Incoming Chairs Message ....1 Outgoing Chairs Message ....2 Message from the Editor..2 ASQ Certification Exam ..3 Know Your Division Team Members..3-4 Inspection Division Strategic Business.4 Plan Activities The Human Calibration Training5-7 Methodology by C. Kotevich Why Do People Believe that ISO & LSS8-9 are Failing by J. Vandenbemden Inspection Division Mid-Year Meeting..9-10 2013-2014 Leadership Team 12 Information on Inspection Division..13 Page 1 of 14
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[Incoming Chairs Message continued from Page 1] Greg is our new Historian and Conference chair I appreciate Gregs devotion and effort he puts in on behalf of our division. You can find a complete list and contact information for the leadership team in this newsletter and on the Inspection Division Internet Site. I encourage you to be involved
Larry Ellison
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Incoming Treasurer: Jackie Schaefer Jackie is currently the Quality Manager at Hampel Corp. a plastics thermoformer in Germantown, WI. She became a member of ASQ in 1994, and has worked with the Inspection Division since 1998 on various activities for the CMI and CQT exams. Besides Quality, she enjoys photography and her pet birds. [Contact: Jackie Schaefer, email: jsscraphappy@gmail.com] Arrangements, Conferene & Events Chair: Jenny Persfull I recently resumed my quality career after a few short years of retirement. I was extremely fortunate to return to Cook Polymer Technologies formerly (Sabin Corporation) a Medical Device Manufacturer. For over thirty years I have worked with quality individuals in my company to ensure that the components we provide our parent and sister companies meet or exceed their expectations. It has been extremely fulfilling knowing that the knowledge Ive gained from my experience can be used by others to help provide a better service to our customers. Ive been active in ASQ local sections and the Inspection Division since the late 1980s. My responsibilities for the Division are to set-up our division planning meeting in the fall and to make sure we have a meeting room at National Congress. [Contact: Jenny Persull, email: Virginia.persfull@cookpolymer.com] scrapbooking,
As the chair of the division I preside at all annual and special meetings of the division and all meetings of the Division Council. I must ensure that the ASQ Code of Ethics is followed within the division. I represent the division at all scheduled Division Affairs Council and group meetings. Assist in develop and ensure implementation of the division strategic business plan and budget. [Contact: John Vandenbemden, email: jfviii@fuse.net]
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Audit Committee Chair works with Division Treasurer to audit Division books, at minimum once a year, at the end of the fiscal year. Auditing activities include inspection and verification of financial records and accounts, receipts and disbursement and actual vs. budget. Coordinates auditing work with committee members. After completion of the audit submits the signed report to ASQ HQ on a timely basis. Observations, findings and recommendations are documented and reported to the Division Council. Newsletter Editor publishes at minimum two enewsletters. Requests newsworthy items from the Members and reviews all received inputs and assembles in the newsletter. Final PDF file is sent to ASQ HQ for uploading to the Division website and communicating to the members. [Contact: Navin S. Dedhia, email: NavinDedhia@hotmail.com]
4. Increase member loyalty Improve member retention * Survey Inspection Division members and formulate action plans based on the survey results *Create network of CQI and CQT training workshops through local colleges/universities in conjunction with local sections 5. Grow Means *Increase ASQ Certifications CQI, CQT Advertise in other publications *Publish bi-annual Inspection Division newsletter *Increase use of ASQ training Incorporate ASQ training schedule in newsletter and website 6. Use technology to enable information sharing *Use discussion board, Face book, Linked-In, Twitter, etc. *Improve performance using Baldrige Critieria or other methodology 7. Increase member leader satisfaction *Create and administer recognition for member team leaders including candidates for Harry Lessig Medal *Participate in DAC meetings to ensure division is represented and to obtain information that may impact member satisfaction 8. People Increase number of member leaders participating in leadership training6.0 P *Increase leadership training beyond the chair for succession and contingency planning 9. Member Recognition *Lead and administer Inspection Division Scholarship Award program *Lead and administer process for selection of Inspector of the year 10. Networking *Hospitality room arrangements at WCQI *Arrange for the annual (in conjunction with WCQI) and mid-year leadership meetings *Plan a Conference either as a cosponsor or stand-alone *submit papers for WCQI
ASQ
* There are more than 270 local member sections Increase number of Member Leaders in more than 14 countries. ASQ divisions and participating in leadership training topics. forums focus on many industries and Division and forum members live all over the world and contribute their professional expertise. 4 ASQ online communities allow ASQ members and the public to contribute to the global voice of * quality. There are more than 212 online * ** communities. Page 4 of 14
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inspections respectively. Sensory inspection for attribute quality is a purely subjective evaluation. The Human Calibration method recognizes the subjective nature of sensory inspection and works with the employees to develop their awareness of how they inspect and how they make a decision. The method is specifically designed to be enjoyable, motivational, productive and non confrontational. Training on subjective attribute inspection touches the hard wired root essence of an individuals personality. The method provides a safe relaxed atmosphere to not cause a defensive reaction which undermines any attempt to calibrate sensory inspectors or operators. Sensory Based Inspection 90% of manufactured parts have non dimensional quality attributes which must be measured manually using sensory based inspection. Visual inspection is the most common form of sensory based inspection but smell, taste, touch (product feel) and sound inspection are critical in some manufacturing industries (e.g. beverages, confection, cosmetics, audio systems etc). All sensory based inspection can be improved using the human calibration method. The Hard Truth about Sensory Based Inspection The decisions made on marginally good parts or marginally bad parts have more to do with the individual inspecting the part than the part itself. There are only 5 possible outcomes when using sensory based inspection for testing physical attributes. A good part is accepted. A bad part is rejected. A good part is rejected. A bad part is accepted. No decision.
A training system to correct Alpha and Beta inspection errors when using sensory based evaluation techniques applicable to Visual Attribute Inspection, Manual Visual Sorting, Onganoleptic Evaluations, Tactile Inspections including Mouth Feel, Sound/Acoustics Quality Inspections. Imagine if All of your employees using sensory based inspection decided to accept or reject a part identically. All of your employees made the same decision on the same parts in a repeatable and accurate manner. The acceptance/rejection rate was consistent based solely on the production quality output regardless of time of day, shift or individual employee. Inspection Errors Cost Money An inspection error occurs when the wrong quality decision is made on an individual part. Rejecting a good part increases operating costs and slows the supply chain. Accepting a bad part increases customer complaints and customer dissatisfaction as well as decreasing the motivation and effectiveness of the sales team. All manufacturing facilities using sensory based acceptance or rejection decisions based on vision or other senses experience inspection errors due to their very subjective nature. Human Calibration Overview Human Calibration is a patent pending training method developed by Crystalline Solutions to calibrate individuals using sensory based (usually visual) evaluation techniques. 90% of manufacturing companies use some form of sensory physical attribute inspection as part of their quality system. Color, shape, size, surface appearance and processing defects are all common visual inspection criteria. Mouth feel, absence of processing aid taste/smell, absence of burnt taste and absence of static/hum/drone noise are common touch, taste, smell and sound based sensory
A very good part is always easy to identify. Inspection errors generally do not come from the misidentification of a very good part unless there is major quality system breakdown. The Human Calibration method does not focus on the decision making ability of employees when presented with a very good part. Very good parts are used during the training as controls and confidence builders. Accepting a good part accurately consistently is one of the two goals of the human Calibration method. As true with a very good part, a very bad part is Page 5 of 14
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rarely misidentified. Inspection errors once again, do not typically come from very bad parts. Inspections once calibrated will correctly identify all bad parts and reject them. Marginally good parts cause 50% of inspection errors. The decision on a marginally good part always has as much to do with the inspectors hard wired bias and personality than the part itself. The Human Calibration method focuses on identifying which employees consistently reject good parts and why. Classified in the Human Calibration method as over rejecters, these individuals unknowingly and with the best of intentions increase operating costs and lengthen lead times. Most customer complaints for quality issues are caused by Beta Inspection Errors. The release of a marginally bad part accounts for the other 50% of inspection errors. Most commonly a company will first recognize inspection errors through the corrective action based on a customer complaint. Individuals who release bad parts based on sensory inspection are classified as under rejecters. The Human Calibration method corrects beta errors using its non confrontational self awareness and coaching technique. According to past session surveys Beta Error correction is the part of the training session the individuals find the most beneficial. Employees never purposefully release bad parts it is an error in judgment based on personal bias - which the Human Calibration method can correct. The Danger of Discipline Discipline is the most common CAPA to correct inspection errors and the most dangerous. Discipline never corrects inspection errors which are due to inspection personality - it only amplifies the problem. For example: an employee disciplined for releasing a bad part will consciously decide to reject all marginal good parts causing a spike in Alpha errors. Conversely, employees disciplined for throwing too much good product away will increase the risk of customer complaints due to beta errors. How does the training Work?
a personality profile for each individual. The session members are classified into one or more of four categories; over rejecters, under rejecters, repeatable but not accurate and not repeatable. Anonymity Yields Truth Using a double blind method of identifying the individual participants only the individuals themselves and the instructor know their scores and how they are classified. Only in a relaxed environment will an individuals true inspection personality come to the forefront. Only once the inspection personality is known can an individual be calibrated. Where do I fit in? The power of self awareness and self calibration is strategically used in combination with verbal coaching to correct inspection errors. The participants will (usually for the first time) understand how they fit in to the inspection team. The Human Calibration method allows anonymous comparisons of the individual participants to themselves (each part is inspected twice at different points in the session), to the group (how do I fit in amongst my peers?) and to the standard (the correct inspection result). Every answer is the correct one The key to success is the ability of each participant to separate the subjective correct answer (based on their personal bias and belief) from the objective correct answer. Sensory inspection is solely based on each individuals ability to understand a set of acceptance/rejection criteria and subjectively apply that knowledge to each inspected part. The Human Calibration method re-enforces the fact that in their own mind, based on personal bias, each individual truly believes they make the correct decision each and every time. Calibration occurs when the individual can objectively compare their internal belief to the knowledge gained during the training and either modify or confirm their end result decision. Coaching is the Key
During a Human Calibration training session the attendees perform hundreds of part inspections. Very little time is spent in a lecture type mode. The basics of the training, background and instructions are explained and the participants get to work immediately. Typically each participant will inspect 240 to 300 parts in a 4 hour session. The results of each inspection are recorded and used to generate
Once the classification rounds are completed, each individual will be coached through the decision making process of both marginally good and marginally bad parts. Success through practice solidifies the training.
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Decision Making Vs. Problem Solving Decision making and problem solving are two completely different thought processes utilizing two separate and distinct parts of the brain. Successful sensory inspection is 100% decision making and 0% problem solving. Decision Making - Is this a bad part? Problem Solving - How did this become a bad part? Typically quality inspectors will focus solely on decision making but in many manufacturing facility operators also perform sensory inspection. Operators occasionally have a difficult time separating decision making from problem solving. During the training session all participants will only use decision making. All parts will be good or bad no distraction of how they got this way or how do I fix them. Dimensional Attributes versus Physical Sensory Attributes Hundreds of millions of dollars per year are spent across all industries calibrating equipment to deliver reliable and repeatable dimensional attribute data. Employees using sensory inspection are never considered in the company calibration program. Human Calibration calibrates people not equipment to deliver reliable and repeatable sensory attribute data. [ Cont act : Christopher Kotevich, Cryst al l i ne Sol ut i ons, 554 G reen dal e Driv e W i ndsor, O nt ari o, Canada N 8S 4A8 , T el : 866-443-6 436, chriskotevich@crystallinesolutions.com www. hum ancali bration. com www. cryst allinesolutions.com ] *8.0 Grow Means Increase professional certifications CQI and CQT
Applications must be postmarked no later than February 15, 2013 [Contact: Jim Spichiger, email: jim.spichiger@alcatel-lucent.com]
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systems can be used to standardize a system to a point where it is over controlled. This occurs because the organization forgets one critical component we must allow are workers to be reactive and creative. When we over control a user will avoid the system or become insensitive to it. Examples of over control are multiple page procedures, numerous procedures in a work area. During a recent audit a process had one operator but had 42 procedures posted in the work area. The user viewed it as wall paper instead of as a tool to assist them in performing their tasks consistently and predictable. The same operator had 13 different forms to complete along with inputting similar data into a computer each shift. When asked why they were capturing all this information the organization indicated that the management system made them do it. This response is improper and totally an incorrect interpretation of the requirements. The management system requirements provide a foundation on what records or procedures are to be created. It does not prescribe a level of control or that one must standardize to paralyze. An organization defines the level of control just as it defines how LSS is used within the organization. If it is used improperly than the expected results should not be surprising. An effective management system and Lean Six Sigma requires a cultural change within the organization. Both require management to share the power. An empowered workforce is creative for LSS effectiveness while the workforce utilizing the management system is always seeking the best practice. When employees speak the I is replaced with We. When we only look out for ourselves and work in a bubble we do not look at a process as a series of inputs or outputs but as only our small piece of the world. Both LSS and management systems that are properly implemented have one key component, they are dynamic systems. You dont see a majority of procedures written 15 years ago still being the majority of the methodology of the system. You do not see the organization say they are a six sigma company because they have 3 black belts and 32 green belts but the last projects conducted by any of the belts was the one they did to obtain the certification. So what drives both Lean Six Sigma and a management system, it is Results. Just like the Malcomb Baldrige Award a world class organization will be identified by not how many belts or how many procedures but in the results that result in their implementation and utilization. I totally agree, stop doing LSS or your management system if you do not Page 8 of 14
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get results. But, it is not the methodologies that failed, it was the implementation and deployment that caused the failure. The methodology is proven, but if an organization did not have results prior to their implementation and still do not have results, the problem is much deeper than the improper implementation of LSS and management systems. [Contact: John Vandenbemden, jfviii@fuse.net]
A column for questions for the experts or comments from members Would you like to see a column where you can ask a question or a comment and anyone can reply to you directly or we can publish an answer in the future newsletters after editing? If so, please do send your question or comments to the editor. Thank you. INSPECTION DIVISION MEMBERSHIPS
Membership Type FULL SENIOR ASSOCIATE FELLOW STUDENT Member Total Sept 2012 1503 1173 100 24 24 2824 Aug 2012 1508 1166 107 24 22 2827
Higlights of the Meeting: John Vandenbemden chaired the meeting in the absence of Larry Ellison. 1. May 20 Minutes of the Meeting was approved as corrected. 2. Review of 2012 Strategic Business Plan measurement/budget 3. Treasurers Report containing expense-income data was presented. 4. Financial audit for the year Jan Dec is conducted prior to Feb 15 deadline. 5. Yearly 2 issues of e-Newsletter are published 6. Reports on Fellow Nomination Review, Membership Data, Harrington Scholarship, Inspector of the Year, Internet Liaison, CQI and CQT Examination support, Standards, Harry Lessig Medal and Nomination were presented. 7. 2013-2014 slate of officers was presented and approved for forwarding to ASQ HQ. No other Nominations were received to the call publicized in the Sept 2012 e-newsletter. The Elected officers for 2013 2014 are; Chair: John Vandenbemden Chair-Elect: Joe Wesling Treasurer: Jackie Schaefer Secretary: Jim Spichiger 8. All attendees participated to create 2013 Strategic Business Plan and budget. 9. Education training and Division conference plan was discussed. 10. Jim Spichiger, Mollie Brown and Navin Dedhia were recognized for their dedication and outstanding contributions to the Division Next Leadership Team Meeting will take place in Indianapolis, Indiana on Sunday, May 5, 2013.
52 23 5 80 2904
51 26 5 82 2909
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[L-R: Carl Drechsel, George Cutler, Gregory Gay, Jackie Schaefer, John Vandenbemden]
[L-R: Front Row Jim Spichiger, Joe Wesling; Middle Row Navin Dedhia, Mollie Brown, Jackie Schaefer, Jenny Persfull, Dale Wells Top Row Carl Drechsel, John Vandenbemden, Gregory Gay, George Culter]
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2011 - 2012 INSPECTION DIVISION LEADERSHIP COUNCIL Chair Larry E. Ellison lellison@nctc.com 812-521-3674 Chair-Elect John Vandenbemden jfviii@fuse.net 859-240-1739 Secretary James Spichiger jim.spichiger@alcatellucent.com 614-718-3571 Treasurer Greg Gay ggandlg@net-link.net 269-496-8311 Nominating Mollie M. Brown molliemc2001@hotmail.com
812- 523-8917
Fellow Examining Greg Gay ggandlg@net-link.net 269-496-8311 Historian Open Internet Liaison George W. Cutler cutlergeorge@gmail.com 908-310-9648 Immediate Past Chair Joy A. Flynn
Joy.Flynn@cookpharmica.com
Policies & Procedures Bruce K. Johnson bjohnson@mdllab.com 781-292-6620 Recognition Jenny Persfull jpersfull@gmail.com 812-369-9622 Scholarship & Awards Jim Spichiger jim.spichiger@alcatellucent.com 614-718-3571 Section Relations
Joe Wesling joe_wesling@hotmail.com 317-814-8449
812-339-4198 Arrangements, Conference & Events Jenny Persfull jpersfull@gmail.com 812-369-9622 Auditing Navin S. Dedhia NavinDedhia@hotmail.com 408-629-1723 Business Planning (QMP) John Vandenbemden jfviii@fuse.net 859-240-1739 Certification Liaison (CQI)
Joe Wesling joe_wesling@hotmail.com 317-814-8449
Membership Chair Jim Spichiger jim.spichiger@alcatellucent.com 614-718-3571 Newsletter Editor Navin S. Dedhia NavinDedhia@hotmail.com 408-629-1723
Standards Liaison Bud Gookins dr.gookins@gmail.com 440-225-1828 WCQI Tech. Programs Mollie M. Brown molliemc2001@hotmail.com
812- 523-8917
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2013 - 2014 INSPECTION DIVISION LEADERSHIP TEAM Elected Officers: Secretary Chair
John Vandenbemden jfviii@fuse.net 859-240-1739 (c) Fax: 866-234-4965
Chair-Elect
Joe Wesling joe_wesling@hotmail. com 262-957-4781
Treasurer
Jackie Schaefer
jackieschaefer@hampel corp.com
262-327-2897
__________________________________________________________________________________________
614-718-3571
Section Relations
Joe Wesling joe_wesling@hotmail.com 262-957-4781
Audit
Navin S. Dedhia NavinDedhia@hotmail.com 408-629-1723
Membership Chair/Global
Carl Drechsel c.drechsel@yahoo.com 832-721-2871
Standards
Bud Gookins dr.gookins@gmail.com 440-225-1828
Newsletter Editor
Navin S. Dedhia NavinDedhia@hotmail.com 408-629-1723
Social Responsibility
Jackie Schaefer
jackieschaefer@hampelcorp.com
262-327-2897
Conference/Meetings
Gregory S. Gay ggandlg@net-link.net 269-496-8311
Nominating
Mollie M. Brown molliemc2001@hotmail.com 812- 523-8917
Historian
Gregory S. Gay ggandlg@net-link.net 269-496-8311
Internet Liaison
George W. Cutler cutlergeorge@gmail.com 908-310-9648
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INSPECTION DIVISION
INTRODUCTION The Inspection Division is dedicated to advancing the theory and practices of Quality Control and Quality Assurance including the skills and science of inspection, test and auditing of products and services. As one of the largest divisions of ASQ the Inspection Division actively seeks to educate and communicate the inspection technologies, techniques, methods, principles, and applications of service and product verification through inspection activities to diverse industries. Quality inspectors and technicians direct organizational improvement with data collected from verification activities, thus helping focus critical resources on vital areas to reduce waste and assure product and service quality. HISTORY The ASQ Inspection Division was founded in 1968. The Division is led by dedicated professionals focused on continuing this critical organizational discipline of quality control and quality assurance JOIN INSPECTION DIVISION Be a leader and advance your career. Join and network with other driven quality professionals volunteering to serve as part of the Division Leadership Team. Obtain access to key day-to-day tools, techniques, ideas and practices vital to product conformance. Advance your organizations business through affective quality principles. Become a member at http://asq.org/join/addforum .html Visit Division Site at www.ASQ.org/inspect DIVISION MISSION To increase customer satisfaction through continuous improvement by disseminating information related to the quality of products and services using inspection and test methodologies. DIVISION SERVICES Certified Quality Inspection CQI >> The Certified Quality Inspector is an inspector who, in support of and under the direction of quality engineers, supervisors, or technicians, can use the proven techniques included in the body of knowledge. Under professional direction, the Quality Inspector evaluates hardware and documentation, performs laboratory procedures, inspects products, measures process performance, records data and prepares formal reports. Certified Quality TECHNICIAN CQT > The Certified Quality Technician is a professional who, in support of and under the direction of quality engineers or supervisors, analyzes and solves quality problems, prepares inspection plans and instructions, selects sampling plan applications, prepares procedures, trains inspectors, performs audits, analyzes quality costs and other quality data, and applies fundamental statistical methods for process control. Chuck Carter Inspector of the Year >> Formal recognition to qualified individuals who spend at least 50% of their time engaged in inspection, test, product audits, calibration, and other related activities that are intended to assure conformance to engineering, manufacturing, quality, and customer standards and requirements H. J. Harrington Scholarship > The ASQ Inspection Division Scholarship was created in 1999 to help members, their family, or friends defray the costs associated with college expenses. In 2011 the ASQ Awards Board approved the name change to H. James Harrington Scholarship. The Inspection Division Leadership Team renamed the scholarship to honor Harrington for his years of service to ASQ. CQI and CQT EXAMS CQI and CQT are supported and developed by the Inspection Division and administered by the ASQ Certification Department. A CQI and CQT has a level of knowledge and experience to pass a required certification exam. ASQ certification is not a license it is an independently verified level of knowledge via a combination of experience, education and examination as monitored and proctored by ASQ
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2013 ASQ World Conference on Quality and Improvement (WCQI) May 6 8, 2013 Indianapolis, Indiana, USA Indiana Convention Center 100 S. Capitol Avenue Indianapolis, IN 46225, USA Theme: Managing Change How will you manage change in 2013 and beyond?
Volunteer Activities to Maximize Your Member Benefits *Actively participate on division committees, programs, publications, newsletter, certifications, etc. *Work with a Leadership Team *Earn Recertification Units (RU) from your volunteer commitment *Support your profession and industry *Get recognized for your contributions
Visit at http://wcqi.asq.org/
To update your contact information, or if you have questions for ASQ, please email help@asq.org.
ASQ is a global community of people passionate about quality, who use the tools, their ideas and expertise to make our world work better. ASQ: The Global Voice of Quality. INSPECTION DIVISION WISHES EVERYONE A HAPPY HOLIDAY SEASON!!!
Navin S. Dedhia Editor, Inspection Division 5080 Bougainvillea Drive San Jose, CA 95111, USA
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