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Dr Usha Mehta
usha.mehta@ieee.org
usha.mehta@nirmauni.ac.in
1
DrUshaMehta22-07-2019
Acknowledgement…..
This presentation has been summarized from
various books, papers, websites and
presentations on VLSI Design and its various
topics all over the world. I couldn’t item-wise
mention from where these large pull of hints and
work come. However, I’d like to thank all
professors and scientists who created such a
good work on this emerging field. Without those
efforts in this very emerging technology, these
notes and slides can’t be finished.
2
DrUshaMehta22-07-2019
Agenda
• Philosophy of Testing
• Why to test
• Do you love to be tested?
• Where do bugs come from?.
• When to test
• When should be your test scheduled?
• How to test
• Verification and Testing in context of
VLSI Design 3
DrUshaMehta22-07-2019
Murphy’s Law…….
- Edward Murphy, An American aerospace engineer who worked
on safety-critical systems
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Nothing is perfect…….
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System Development …
Project Starts here….
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Courtesy: https://asiketltestanalyst.wordpress.com/tag/tom-and-jerry/
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Tom has forgotten that
“Nothing is perfect…….”
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• Intel, producer of the affected chip,
claims that the common user would
experience it once every 27,000 years
while IBM, manufacturer of a chip
competing with Intel's Pentium, claims
that the common user would experience
it once every 24 days
• Loss of $475 million
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If testing is so important, why do
people not test it thoroughly?
• To save money
• To save time
• To hide the inefficiencies
• ….
29
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Tester…from Designer point of view…..
• The relationship between the tester and
everyone else in the project team has
been like ….
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Why so love-hate relationship?
Can you prove the lion exists ?
Can you prove the ghost does exits ? Or does
not exist?
Testing can only show
the presence of errors,
never their absence.
-Edsger Djikstra
31
DrUshaMehta22-07-2019
Tester…..
From Production House point of view…..
“Bugfree Design”
does not give any extra revenue
but
bugs in design are very costly!!!!
32
DrUshaMehta22-07-2019
• Costly re-spin(s)
• Companies may miss out
market window
• Large companies can have
reputation at stake – e.g.
Pentium Bug
• Smaller companies can
have hard to recover
financial implications
• For start-ups, their
existence itself can be at
stake!
33
DrUshaMehta22-07-2019
Respin….
65 % of chips fail at first silicon
Tester…..
From Production House point of view…..
Tester…..
From User Point of View…..
34
DrUshaMehta22-07-2019
Does user really value testing?
Tester
Designer
Does not love
Consumer
does not
care
Production
house
Does not want 35
DrUshaMehta22-07-2019
Even though…..
testing is important…..
36
DrUshaMehta22-07-2019
• Does testing directly generate any
revenue?
• Does designer like testing?
• Does it generate “trust” ?
• Does trust generate “reusability”?
• Does reusability generate “revenue”?
Why testing is of too much
importance in today’s
semiconductor world…..
• In Earlier days, design had all the
glamour and testing was considered to
be a dirty job, but now…
37
DrUshaMehta22-07-2019
[Courtesy: ITRS]
Testing and Verification in Current
Scenario
• While the silicon capacity continues to increase along the
Moore’s law, the efforts required to verify these designs have
increased even a greater rate : doubling roughly every six to
nine months.
• In the era of multimillion gate Asics, reusable IPs, and SoC
designs, 70% of the total efforts consumed by verification
and testing.
• Number of verification, validation, testing engineer is three
the number of RTL design engineer
• When design projects are completed, test benches makes up
80% of the total code volume.
• Most of the job openings in India is in this
field.
• Design Hubs in Ahmedabad/Gujarat???
• Verification Hubs in
Ahmedabad/Gujarat???
38
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Once they grow……
40
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Cost – Rule of 10
It costs 10 times more to test a device as we move to higher
level in the product manufacturing process
41
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• Design Errors
• Misinterpretation of specification
• Fabrication Errors
• Wrong component
• Incorrect Wiring
• Fabrication Defects
• Imperfect Process Variations
• Physical Failure
• During life time of a system
22-07-2019DrUshaMehta
42
ASIC Design Flow
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DrUshaMehta22-07-2019
Architectural
Behavioural
RTL
Gate
Transistor
Physical
Unpacked Chip
44
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Circuit
Chip, Components, Interconnects…
System
System on Chip
Network on Chip
Prototype Testing
Mass Production Testing
System @ Field
Role of Testing in General
• Verification
• will any fault occur?
• Validation
• will fault occur during mass production?
• Detection
• Is there any fault? Yes or no?
• Diagnosis
• Where is the fault?
• Device Characterization
• Why the fault occurred? (Is design wrong or test process wrong?)
• Failure Mode Analysis (FMA)
• How that fault can be prevented? (Is manufacturing process wrong?)
• Burn-In
• Will it work for longer life?
• Speed Binning
• What is the speed of device?
• Acceptance Testing/Incoming Inspection
• Should I use it in my system?
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DrUshaMehta22-07-2019
Verification
• Verifies the correctness of Design
• Performed once prior to manufacturing
process
• Performed by simulation, hardware
emulation or formal methods
• Responsible for quality of design
• Like sonography used for unborn baby
during pregnancy
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DrUshaMehta22-07-2019
Validation
Verification Testing/Characterization / Design Debug
• After the first lot of prototypes are
manufactured, IC goes through, design
validation/pilot-run stage.
• It checks that either the fabrication process
was correct and fabricated IC is correct. ( Here
it is assumed that design was error free)
• Also verifies the correctness of test procedure.
• AC, DC, Functional Test
• Probing internal chip nodes also
• Special tools like scanning electron
Microscope, electron beam scanner, artificial
intelligent technique etc, are used
• Like Newborn sreening tests for baby
47
DrUshaMehta22-07-2019
Diagnosis
• Identify the fault that exists in system.
• Which fault is there (type of fault)?
• Where is that fault (fault location)?
• Like after a set of pathological test, the
doctor diagnosis your disease.
48
DrUshaMehta22-07-2019
Device Characterization
• Determination and correction of errors
in device and/or test procedure
• So that the next lot of IC will be error
free.
• Like doctor writes a prescription of
medicine to cure your disease.
• Here there is a difference between man
and IC!!!!!!!!!
49
DrUshaMehta22-07-2019
Failure Mode Analysis
• Why/How/when the fault had occurred?
• Determine the manufacturing process
errors that may have caused the fault.
• Like determining why that disease
occurred and find the preventive actions
(bad health /food habits) which created
disease
50
DrUshaMehta22-07-2019
Detection (testing in general…)
• Does any of the fault exists?
• Which, why, how, where, when is out of scope here.
• Only YES/NO. Go/No Go test for IC to be shipped to market
or not.
• At fabrication unit
• For all fabricated IC
• Less comprehensive than characterization
• Test should have high fault coverage, low cost and minimum
test time
• Are you completely fit? Does any of the disease
there?
• Like medical test for army ( if fit then go, otherwise
no go)
51
DrUshaMehta22-07-2019
Burn-In/Stress Test
• To stress the chip to accelerate the
failure mechanism
• Some chip passes the production test
but will fail very quickly thereafter
• To increase temp and/or voltage while
applying test patterns
• Infant Mortality Failures: 10-30 Hrs
• Freak Failure: 100-1000Hrs
52
DrUshaMehta22-07-2019
Acceptance Testing/
Incoming Inspection
• Customer performs this test
• Like universal tester to test the IC at our
Digital Electronics Labs
53
DrUshaMehta22-07-2019
Place of Verification in Design Flow
• Specification
• Finalization of
specification
• Behavioural
Description/RTL code
• Functional Verification
• Gate level netlist
• Static timing analysis
• Circuit level
• Propagation delay
• Physical Domain
• Layout vs Schematic
(LVS)
• During Fabrication
• Wafer testing
• Pilot lot production
• Validation
• Mass production
• Testing
• Burn-In
• Speed Binning
• Yield loss
• Diagnosis
• Failure Mode
Analysis
• Before use
• Acceptance/Incomin
g Testing
• In-System
54
DrUshaMehta22-07-2019
Verification
• On Design
(functionality,
estimated speed)
• Pre-silicon
• One time
• Methods:
• Simulation
• Emulation
• formal methods
• A Design Bug
• Makes all Fabricated
IC useless
Detection/Testing
• On Device
(manufactured
hardware)
• Post-Silicon
• On all ICs, i.e. every
time IC is fabricated
• Methods:
• Test Generation
• Test Application
• A fabrication defect
• May cause all ICs or
Some of the ICs
useless. 55
DrUshaMehta22-07-2019
TTM : Time-to-MONEY
56
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Validation Test
Failure Rate vs Product Life Time
57
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Software Failure Rate
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Test Principal for Digital Circuits
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61
DrUshaMehta22-07-2019
Mid Test….
 Calculate the time required to test a 64 bit
adder at the speed of 1 GHz
 64 bit adder => 129 inputs, 65 outputs
• Is it possible????????????????????????
• The manufacturing house wants to complete
it into few mins only. 62
DrUshaMehta22-07-2019
63
DrUshaMehta22-07-2019
Thanks……

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2019 1 testing and verification of vlsi design_introduction

  • 2. Acknowledgement….. This presentation has been summarized from various books, papers, websites and presentations on VLSI Design and its various topics all over the world. I couldn’t item-wise mention from where these large pull of hints and work come. However, I’d like to thank all professors and scientists who created such a good work on this emerging field. Without those efforts in this very emerging technology, these notes and slides can’t be finished. 2 DrUshaMehta22-07-2019
  • 3. Agenda • Philosophy of Testing • Why to test • Do you love to be tested? • Where do bugs come from?. • When to test • When should be your test scheduled? • How to test • Verification and Testing in context of VLSI Design 3 DrUshaMehta22-07-2019
  • 4. Murphy’s Law……. - Edward Murphy, An American aerospace engineer who worked on safety-critical systems 4 DrUshaMehta22-07-2019
  • 7. System Development … Project Starts here…. 7 DrUshaMehta22-07-2019 Courtesy: https://asiketltestanalyst.wordpress.com/tag/tom-and-jerry/
  • 10. Tom has forgotten that “Nothing is perfect…….” 10 DrUshaMehta22-07-2019
  • 25. • Intel, producer of the affected chip, claims that the common user would experience it once every 27,000 years while IBM, manufacturer of a chip competing with Intel's Pentium, claims that the common user would experience it once every 24 days • Loss of $475 million 25 DrUshaMehta22-07-2019
  • 29. If testing is so important, why do people not test it thoroughly? • To save money • To save time • To hide the inefficiencies • …. 29 DrUshaMehta22-07-2019
  • 30. Tester…from Designer point of view….. • The relationship between the tester and everyone else in the project team has been like …. 30 DrUshaMehta22-07-2019
  • 31. Why so love-hate relationship? Can you prove the lion exists ? Can you prove the ghost does exits ? Or does not exist? Testing can only show the presence of errors, never their absence. -Edsger Djikstra 31 DrUshaMehta22-07-2019
  • 32. Tester….. From Production House point of view….. “Bugfree Design” does not give any extra revenue but bugs in design are very costly!!!! 32 DrUshaMehta22-07-2019
  • 33. • Costly re-spin(s) • Companies may miss out market window • Large companies can have reputation at stake – e.g. Pentium Bug • Smaller companies can have hard to recover financial implications • For start-ups, their existence itself can be at stake! 33 DrUshaMehta22-07-2019 Respin…. 65 % of chips fail at first silicon Tester….. From Production House point of view…..
  • 34. Tester….. From User Point of View….. 34 DrUshaMehta22-07-2019 Does user really value testing?
  • 35. Tester Designer Does not love Consumer does not care Production house Does not want 35 DrUshaMehta22-07-2019
  • 36. Even though….. testing is important….. 36 DrUshaMehta22-07-2019 • Does testing directly generate any revenue? • Does designer like testing? • Does it generate “trust” ? • Does trust generate “reusability”? • Does reusability generate “revenue”?
  • 37. Why testing is of too much importance in today’s semiconductor world….. • In Earlier days, design had all the glamour and testing was considered to be a dirty job, but now… 37 DrUshaMehta22-07-2019 [Courtesy: ITRS]
  • 38. Testing and Verification in Current Scenario • While the silicon capacity continues to increase along the Moore’s law, the efforts required to verify these designs have increased even a greater rate : doubling roughly every six to nine months. • In the era of multimillion gate Asics, reusable IPs, and SoC designs, 70% of the total efforts consumed by verification and testing. • Number of verification, validation, testing engineer is three the number of RTL design engineer • When design projects are completed, test benches makes up 80% of the total code volume. • Most of the job openings in India is in this field. • Design Hubs in Ahmedabad/Gujarat??? • Verification Hubs in Ahmedabad/Gujarat??? 38 DrUshaMehta22-07-2019
  • 40. Once they grow…… 40 DrUshaMehta22-07-2019 Cost – Rule of 10 It costs 10 times more to test a device as we move to higher level in the product manufacturing process
  • 42. • Design Errors • Misinterpretation of specification • Fabrication Errors • Wrong component • Incorrect Wiring • Fabrication Defects • Imperfect Process Variations • Physical Failure • During life time of a system 22-07-2019DrUshaMehta 42
  • 44. Architectural Behavioural RTL Gate Transistor Physical Unpacked Chip 44 DrUshaMehta22-07-2019 Circuit Chip, Components, Interconnects… System System on Chip Network on Chip Prototype Testing Mass Production Testing System @ Field
  • 45. Role of Testing in General • Verification • will any fault occur? • Validation • will fault occur during mass production? • Detection • Is there any fault? Yes or no? • Diagnosis • Where is the fault? • Device Characterization • Why the fault occurred? (Is design wrong or test process wrong?) • Failure Mode Analysis (FMA) • How that fault can be prevented? (Is manufacturing process wrong?) • Burn-In • Will it work for longer life? • Speed Binning • What is the speed of device? • Acceptance Testing/Incoming Inspection • Should I use it in my system? 45 DrUshaMehta22-07-2019
  • 46. Verification • Verifies the correctness of Design • Performed once prior to manufacturing process • Performed by simulation, hardware emulation or formal methods • Responsible for quality of design • Like sonography used for unborn baby during pregnancy 46 DrUshaMehta22-07-2019
  • 47. Validation Verification Testing/Characterization / Design Debug • After the first lot of prototypes are manufactured, IC goes through, design validation/pilot-run stage. • It checks that either the fabrication process was correct and fabricated IC is correct. ( Here it is assumed that design was error free) • Also verifies the correctness of test procedure. • AC, DC, Functional Test • Probing internal chip nodes also • Special tools like scanning electron Microscope, electron beam scanner, artificial intelligent technique etc, are used • Like Newborn sreening tests for baby 47 DrUshaMehta22-07-2019
  • 48. Diagnosis • Identify the fault that exists in system. • Which fault is there (type of fault)? • Where is that fault (fault location)? • Like after a set of pathological test, the doctor diagnosis your disease. 48 DrUshaMehta22-07-2019
  • 49. Device Characterization • Determination and correction of errors in device and/or test procedure • So that the next lot of IC will be error free. • Like doctor writes a prescription of medicine to cure your disease. • Here there is a difference between man and IC!!!!!!!!! 49 DrUshaMehta22-07-2019
  • 50. Failure Mode Analysis • Why/How/when the fault had occurred? • Determine the manufacturing process errors that may have caused the fault. • Like determining why that disease occurred and find the preventive actions (bad health /food habits) which created disease 50 DrUshaMehta22-07-2019
  • 51. Detection (testing in general…) • Does any of the fault exists? • Which, why, how, where, when is out of scope here. • Only YES/NO. Go/No Go test for IC to be shipped to market or not. • At fabrication unit • For all fabricated IC • Less comprehensive than characterization • Test should have high fault coverage, low cost and minimum test time • Are you completely fit? Does any of the disease there? • Like medical test for army ( if fit then go, otherwise no go) 51 DrUshaMehta22-07-2019
  • 52. Burn-In/Stress Test • To stress the chip to accelerate the failure mechanism • Some chip passes the production test but will fail very quickly thereafter • To increase temp and/or voltage while applying test patterns • Infant Mortality Failures: 10-30 Hrs • Freak Failure: 100-1000Hrs 52 DrUshaMehta22-07-2019
  • 53. Acceptance Testing/ Incoming Inspection • Customer performs this test • Like universal tester to test the IC at our Digital Electronics Labs 53 DrUshaMehta22-07-2019
  • 54. Place of Verification in Design Flow • Specification • Finalization of specification • Behavioural Description/RTL code • Functional Verification • Gate level netlist • Static timing analysis • Circuit level • Propagation delay • Physical Domain • Layout vs Schematic (LVS) • During Fabrication • Wafer testing • Pilot lot production • Validation • Mass production • Testing • Burn-In • Speed Binning • Yield loss • Diagnosis • Failure Mode Analysis • Before use • Acceptance/Incomin g Testing • In-System 54 DrUshaMehta22-07-2019
  • 55. Verification • On Design (functionality, estimated speed) • Pre-silicon • One time • Methods: • Simulation • Emulation • formal methods • A Design Bug • Makes all Fabricated IC useless Detection/Testing • On Device (manufactured hardware) • Post-Silicon • On all ICs, i.e. every time IC is fabricated • Methods: • Test Generation • Test Application • A fabrication defect • May cause all ICs or Some of the ICs useless. 55 DrUshaMehta22-07-2019
  • 57. Failure Rate vs Product Life Time 57 DrUshaMehta22-07-2019
  • 60. Test Principal for Digital Circuits 60 DrUshaMehta22-07-2019
  • 62. Mid Test….  Calculate the time required to test a 64 bit adder at the speed of 1 GHz  64 bit adder => 129 inputs, 65 outputs • Is it possible???????????????????????? • The manufacturing house wants to complete it into few mins only. 62 DrUshaMehta22-07-2019
  • 64.