VLSI

VLSI Testing
Testing

Lecture
Lecture 1:
1: Introduction
Introduction

Dr. Vishwani D. Agrawal

James J. Danaher Professor of Electrical and
Computer Engineering
Auburn University, Alabama 36849, USA
vagrawal@[Link]
[Link]

IIT Delhi, July 24, 2012, 3:00-4:00PM

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 1

 Course
Course Description
Description
This course is designed for the MTech program
in VLSI at IIT, Delhi. It is patterned after a one-
semester graduate-level course offered at
Auburn University. A set of 17 lectures that
include classroom exercises provide
understanding of theoretical and practical
aspects of VLSI testing. The course fulfills the
needs of today’s industrial design
environment, which demands knowledge of
testing concepts of digital, memory, analog
and radio frequency (RF) subsystems often
implemented on a system-on-chip (SoC).

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 2

 Outline
Outline
 Lecture 1: Introduction (19*+1) * Number of slides
 Lecture 2: Yield and quality (17+2)
 Lecture 3: Fault modeling (20+2)
 Lecture 4: Testability analysis (27)
 Lecture 5: Logic simulation (15)
 Lecture 6: Fault simulation (19)
 Lecture 7: Combinational ATPG (24+3)
 Lecture 8: Sequential ATPG (19+2)
 Lecture 9: Delay test (26)
 Lecture 10: Memory test (26)
 Lecture 11: Analog test (27)
 Lecture 12: Model-Based and Alternate Test (15)
 Lecture 13: DFT and Scan (23+2)
 Lecture 14: BIST (29)
 Lecture 15: System diagnosis (21)
 Lecture 16: RF Testing: Introduction, gain measurement (39)
 Lecture 17: RF Testing: Intermodulation and noise measurements (34)

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 3

 Schedule
Schedule
 July 24, 2012 – 3-5PM Lectures 1 and 2
 July 24, 2012 – Homework 1 assigned, due July 26
 July 25, 2012 – 3-5PM Lectures 3 and 4
 July 26, 2012 – 3-5PM Lectures 5 and 6
 July 27, 2012 – 3-5PM Lectures 7 and 8
 July 28, 2012 – 8-10AM Lectures 9 and 10
 July 30, 2012 – 3-5PM Lectures 11 and 12
 July 30, 2012 – Homework 2 assigned, due Aug 1
 July 31, 2012 – 3-5PM Lectures 13 and 14
 Aug 1, 2012 – 3-5PM Lectures 15 and 16
 Aug 1, 2012 – Take-Home Exam assigned
 Aug 3, 2012 – 3-4PM Lectures 17
 Aug 3, 2012 –Take-Home Exam due 5PM

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 4

 Introduction
Introduction
 VLSI realization process
 Verification and test
 Ideal and real tests
 Costs of testing
 Roles of testing
 A modern VLSI device - system-on-a-chip
 Testing
Digital
Memory
Analog
RF
 Textbook
 Problem to solve
Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 5
 VLSI
VLSI Realization
Realization Process
Process
Customer’s need

Determine requirements

Write specifications

Design synthesis and Verification

Test development
Fabrication
Manufacturing test

Chips to customer
Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 6
 Definitions
Definitions
 Design synthesis: Given an I/O function, develop a
procedure to manufacture a device using known
materials and processes.
 Verification: Predictive analysis to ensure that the
synthesized design, when manufactured, will perform
the given I/O function.
 Test: A manufacturing step that ensures that the
physical device, manufactured from the synthesized
design, has no manufacturing defect.

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 7

 Verification
Verification vs.
vs. Test
Test
Verification Test
 Verifies correctness of  Verifies correctness of
design. manufactured hardware.
 Performed by simulation,  Two-part process:
hardware emulation, or 1. Test generation: software
formal methods. process executed once
during design
2. Test application: electrical
tests applied to hardware
 Performed once prior to  Test application performed on
manufacturing. every manufactured device.
 Responsible for quality of  Responsible for quality of
design. devices.

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 8

 Problems
Problems of
of Ideal
Ideal Tests
Tests
 Ideal tests detect all defects produced in the
manufacturing process.
 Ideal tests pass all functionally good devices.
 Very large numbers and varieties of possible
defects need to be tested.
 Difficult to generate tests for some real defects.
Defect-oriented testing is an open problem.

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 9

 Real
Real Tests
Tests
 Based on analyzable fault models, which may not
map on real defects.
 Incomplete coverage of modeled faults due to
high complexity.
 Some good chips are rejected. The fraction (or
percentage) of such chips is called the yield loss.
 Some bad chips pass tests. The fraction (or
percentage) of bad chips among all passing chips
is called the defect level.

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 10

 Testing
Testing as
as Filter
Filter Process
Process
Good chips Prob(pass test) = high Mostly
good
Prob(good) = y Pr w
o l o chips
b(
fai t)=
s
l te
Fabricated Tested
s te
chips s st chips
)=
( pa l ow
o b
Pr
Defective chips Mostly
bad
Prob(bad) = 1- y Prob(fail test) = high chips

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 11

 Costs
Costs of
of Testing
Testing
 Design for testability (DFT)
Chip area overhead and yield reduction
Performance overhead
 Software processes of test
Test generation and fault simulation
Test programming and debugging
 Manufacturing test
Automatic test equipment (ATE) capital cost
Test center operational cost

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 12

 Present
Present and
and Future*
Future*

* SIA Roadmap from [Link], July 23, 2012

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 13

Design
Design for
for Testability
Testability (DFT)
(DFT)
DFT refers to hardware design styles or added hardware
that reduces test generation complexity.
Motivation: Test generation complexity increases
exponentially with the size of the circuit.
Example: Test hardware applies tests to blocks A
and B and to internal bus; avoids test generation
for combined A and B blocks.
Int.
Primary Logic bus Primary
Logic
inputs block A outputs
block B
(PI) (PO)
Test Test
input output
Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 14
 Cost
Cost of
of Manufacturing
Manufacturing
Test
Test in
in 2000AD
2000AD
 0.5-1.0GHz digital clock; analog instruments; 1,024
digital pins: ATE purchase price
= $1.2M + 1,024 x $3,000 = $4.272M
 Annual running cost (five-year linear depreciation)
= Depreciation (20%) + Maintenance (2%) + Operation ($0.5M)
= $0.854M + $0.085M + $0.5M
= $1.439M/year
 Test cost (24 hour ATE operation)
= $1.439M/(365 x 24 x 3,600)
= 4.5 cents/second
Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 15
 Roles
Roles of
of Testing
Testing
 Detection: Determination whether or not the device
under test (DUT) has some fault.
 Diagnosis: Identification of a specific fault that is
present on DUT.
 Device characterization: Determination and
correction of errors in design and/or test
procedure.
 Failure mode analysis (FMA): Determination of
manufacturing process errors that may have
caused defects on the DUT.

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 16

 A
A Modern
Modern VLSI
VLSI Device
Device
System-on-Chip
System-on-Chip (SOC)
(SOC)
DSP RAM
core ROM
Data Transmission
terminal medium
Inter- Mixed-
face signal
logic Codec

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 17

 Textbooks
Textbooks
 Digital, memory and mixed-signal:
M. L. Bushnell and V. D. Agrawal, Essentials of Electronic Testing for Digital, Memory
and Mixed-Signal VLSI Circuits, Springer, 2000.
[Link]

 RF testing
1. J. Kelly and M. Engelhardt, Advanced Production Testing of RF, SoC, and SiP Devices,
Boston: Artech House, 2007.
2. B. Razavi, RF Microelectronics, Upper Saddle River, New Jersey: Prentice Hall PTR, 1998.
3. K. B. Schaub and J. Kelly, Production Testing of RF and System-on-a-chip Devices for
Wireless Communications, Boston: Artech House, 2004.

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 18

 A
A Problem
Problem to
to Solve
Solve
 Using the testing cost obtained in Slide 15, determine what
is the component of test in the cost of a mixed-signal VLSI
chip for the following data:
Analog test time = 1.5 s
Digital test clock = 200MHz
Number of digital test vectors = 109
Chip yield = 70%

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 19

 Solution
Solution
Assuming that one vector is applied per clock cycle during the digital test, the
rate of test application is 200 million vectors per second. Therefore,
Digital test time = (1000 × 106)/(200× 106) = 5 seconds

Adding the analog test time, we get,

Total test time = 1.5 + 5.0 = 6.5 seconds

The testing cost for a 500 MHz, 1,024 pin tester was obtained as 4.56 cents in
Slide 15. Thus,
Cost of testing a chip = 6.5 × 4.56 = 29.64 cents

The cost of testing bad chips should also be recovered from the price of good
chips. Since the yield of good chips is 70%, we obtain
Test cost per each good chip = 29.64/0.7 ≈ 42 cents

42 cents should be included as the cost of testing while figuring out the
price of chips.

Copyright 2001, Agrawal & Bushnell Lecture 1 Introduction 20