Fundamentals of Digital Test and DFT Vishwani D. Agrawal Rutgers University, Dept. of ECE New Jersey http://cm.bell-labs.com/cm/cs/who/va January 2003 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Course Outline Basic concepts and definitions Fault modeling Fault simulation ATPG DFT and scan design BIST Boundary scan IDDQ test 2003 Agrawal: Digital Test and DFT

VLSI Realization Process Customer’s need Determine requirements Write specifications Design synthesis and Verification Test development Fabrication Manufacturing test Chips to customer 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT 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. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Realities of Tests Based on analyzable fault models, which may not map onto 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. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Costs of 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 2003 Agrawal: Digital Test and DFT

Cost of Manufacturing Testing in 2000AD 0.5-1.0GHz, analog instruments,1,024 digital pins: ATE purchase price = $1.2M + 1,024 x $3,000 = $4.272M Running cost (five-year linear depreciation) = Depreciation + Maintenance + Operation = $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 2003 Agrawal: Digital Test and DFT

Present and Future* 1997--2001 2003--2006 Feature size (micron) 0.25 - 0.15 0.13 - 0.10 Transistors/sq. cm 4 - 10M 18 - 39M Pin count 100 - 900 160 - 1475 Clock rate (MHz) 200 - 730 530 - 1100 Power (Watts) 1.2 - 61 2 - 96 * SIA Roadmap, IEEE Spectrum, July 1999 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Method of Testing 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT ADVANTEST Model T6682 ATE 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT LTX FUSION HF ATE 2003 Agrawal: Digital Test and DFT

VLSI Chip Yield A manufacturing defect is a finite chip area with electrically malfunctioning circuitry caused by errors in the fabrication process. A chip with no manufacturing defect is called a good chip. Fraction (or percentage) of good chips produced in a manufacturing process is called the yield. Yield is denoted by symbol Y. Cost of a chip: Cost of fabricating and testing a wafer -------------------------------------------------------------------- Yield x Number of chip sites on the wafer 2003 Agrawal: Digital Test and DFT

Defect Level or Reject Ratio Defect level (DL) is the ratio of faulty chips among the chips that pass tests. DL is measured as parts per million (ppm). DL is a measure of the effectiveness of tests. DL is a quantitative measure of the manufactured product quality. For commercial VLSI chips a DL greater than 500 ppm is considered unacceptable. 2003 Agrawal: Digital Test and DFT

Example: SEMATECH Chip Bus interface controller ASIC fabricated and tested at IBM, Burlington, Vermont 116,000 equivalent (2-input NAND) gates 304-pin package, 249 I/O Clock: 40MHz, some parts 50MHz 0.45m CMOS, 3.3V, 9.4mm x 8.8mm area Full scan, 99.79% fault coverage Advantest 3381 ATE, 18,466 chips tested at 2.5MHz test clock Data obtained courtesy of Phil Nigh (IBM) 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Computed DL 237,700 ppm (Y = 76.23%) Defect level in ppm Stuck-at fault coverage (%) 2003 Agrawal: Digital Test and DFT

Summary: Introduction VLSI Yield drops as chip area increases; low yield means high cost Fault coverage measures the test quality Defect level (DL) or reject ratio is a measure of chip quality DL can be determined by an analysis of test data For high quality: DL < 500 ppm, fault coverage ~ 99% 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Fault Modeling 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Why Model Faults? I/O function tests inadequate for manufacturing (functionality versus component and interconnect testing) Real defects (often mechanical) too numerous and often not analyzable A fault model identifies targets for testing A fault model makes analysis possible Effectiveness measurable by experiments 2003 Agrawal: Digital Test and DFT

Some Real Defects in Chips Processing defects Missing contact windows Parasitic transistors Oxide breakdown . . . Material defects Bulk defects (cracks, crystal imperfections) Surface impurities (ion migration) Time-dependent failures Dielectric breakdown Electromigration Packaging failures Contact degradation Seal leaks Ref.: M. J. Howes and D. V. Morgan, Reliability and Degradation - Semiconductor Devices and Circuits, Wiley, 1981. 2003 Agrawal: Digital Test and DFT

Observed PCB Defects Defect classes Occurrence frequency (%) Shorts 51 Opens Missing components Wrong components Reversed components Bent leads Analog specifications Digital logic Performance (timing) Occurrence frequency (%) 51 1 6 13 8 5 Ref.: J. Bateson, In-Circuit Testing, Van Nostrand Reinhold, 1985. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Common Fault Models Single stuck-at faults Transistor open and short faults Memory faults PLA faults (stuck-at, cross-point, bridging) Functional faults (processors) Delay faults (transition, path) Analog faults For more examples, see Section 4.4 (p. 60-70) of the book. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Single Stuck-at Fault Three properties define a single stuck-at fault Only one line is faulty The faulty line is permanently set to 0 or 1 The fault can be at an input or output of a gate Example: XOR circuit has 12 fault sites ( ) and 24 single stuck-at faults Faulty circuit value Good circuit value c j 0(1) s-a-0 a d 1(0) g 1 h z i 1 b e 1 k f Test vector for h s-a-0 fault 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Fault Equivalence Number of fault sites in a Boolean gate circuit = #PI + #gates + #(fanout branches). Fault equivalence: Two faults f1 and f2 are equivalent if all tests that detect f1 also detect f2. If faults f1 and f2 are equivalent then the corresponding faulty functions are identical. Fault collapsing: All single faults of a logic circuits can be divided into disjoint equivalence subsets, where all faults in a subset are mutually equivalent. A collapsed fault set contains one fault from each equivalence subset. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Equivalence Example sa0 sa1 Faults in red removed by equivalence collapsing sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 sa0 sa1 20 Collapse ratio = ----- = 0.625 32 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Summary: Fault Models Fault models are analyzable approximations of defects and are essential for a test methodology. For digital logic single stuck-at fault model offers best advantage of tools and experience. Many other faults (bridging, stuck-open and multiple stuck-at) are largely covered by stuck-at fault tests. Stuck-short and delay faults and technology-dependent faults require special tests. Memory and analog circuits need other specialized fault models and tests. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Fault Simulation 2003 Agrawal: Digital Test and DFT

Problem and Motivation Fault simulation Problem: Given A circuit A sequence of test vectors A fault model Determine Fault coverage - fraction (or percentage) of modeled faults detected by test vectors Set of undetected faults Motivation Determine test quality and in turn product quality Find undetected fault targets to improve tests 2003 Agrawal: Digital Test and DFT

Fault simulator in a VLSI Design Process Verification input stimuli Verified design netlist Fault simulator Test vectors Modeled fault list Remove tested faults Test compactor Delete vectors Fault coverage ? Low Test generator Add vectors Adequate Stop 2003 Agrawal: Digital Test and DFT

Fault Simulation Scenario Circuit model: mixed-level Mostly logic with some switch-level for high-impedance (Z) and bidirectional signals High-level models (memory, etc.) with pin faults Signal states: logic Two (0, 1) or three (0, 1, X) states for purely Boolean logic circuits Four states (0, 1, X, Z) for sequential MOS circuits Timing: Zero-delay for combinational and synchronous circuits Mostly unit-delay for circuits with feedback 2003 Agrawal: Digital Test and DFT

Fault Simulation Scenario (continued) Mostly single stuck-at faults Sometimes stuck-open, transition, and path-delay faults; analog circuit fault simulators are not yet in common use Equivalence fault collapsing of single stuck-at faults Fault-dropping -- a fault once detected is dropped from consideration as more vectors are simulated; fault-dropping may be suppressed for diagnosis Fault sampling -- a random sample of faults is simulated when the circuit is large 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Essence of Fault Sim. Test vectors Fault-free circuit Comparator f1 detected? Circuit with fault f1 Comparator f2 detected? Circuit with fault f2 Comparator fn detected? Circuit with fault fn Disadvantage: Much repeated computation; CPU time prohibitive for VLSI circuits Alternative: Simulate many faults together 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Fault Sampling A randomly selected subset (sample) of faults is simulated. Measured coverage in the sample is used to estimate fault coverage in the entire circuit. Advantage: Saving in computing resources (CPU time and memory.) Disadvantage: Limited data on undetected faults. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Random Sampling Model Detected fault Undetected fault All faults with a fixed but unknown coverage Random picking Np = total number of faults (population size) C = fault coverage (unknown) Ns = sample size Ns << Np c = sample coverage (a random variable) 2003 Agrawal: Digital Test and DFT

Probability Density of Sample Coverage, c (x--C )2 -- ------------ 1 2s 2 p (x ) = Prob(x < c < x +dx ) = -------------- e s (2 p) 1/2 C (1 - C) Variance, s 2 = ------------ Ns Sampling error s s p (x ) Mean = C x C -3s x C +3s 1.0 C Sample coverage 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Sampling Error Bounds C (1 - C ) | x - C | = 3 [ -------------- ] 1/2 Ns Solving the quadratic equation for C, we get the 3-sigma (99.7% confidence) estimate: 4.5 C 3s = x ------- [1 + 0.44 Ns x (1 - x )]1/2 Ns Where Ns is sample size and x is the measured fault coverage in the sample. Example: A circuit with 39,096 faults has an actual fault coverage of 87.1%. The measured coverage in a random sample of 1,000 faults is 88.7%. The above formula gives an estimate of 88.7% 3%. CPU time for sample simulation was about 10% of that for all faults. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Summary: Fault Sim. Fault simulator is an essential tool for test development. Concurrent fault simulation algorithm offers the best choice. For restricted class of circuits (combinational and synchronous sequential with only Boolean primitives), differential algorithm can provide better speed and memory efficiency (Section 5.5.6.) For large circuits, the accuracy of random fault sampling only depends on the sample size (1,000 to 2,000 faults) and not on the circuit size. The method has significant advantages in reducing CPU time and memory needs of the simulator. 2003 Agrawal: Digital Test and DFT

Automatic Test-pattern Generation (ATPG) 2003 Agrawal: Digital Test and DFT

Functional vs. Structural ATPG 2003 Agrawal: Digital Test and DFT

Functional vs. Structural (Continued) Functional ATPG – generate complete set of tests for circuit input-output combinations 129 inputs, 65 outputs: 2129 = 680,564,733,841,876,926,926,749, 214,863,536,422,912 patterns Using 1 GHz ATE, would take 2.15 x 1022 years Structural test: No redundant adder hardware, 64 bit slices Each with 27 faults (using fault equivalence) At most 64 x 27 = 1728 faults (tests) Takes 0.000001728 s on 1 GHz ATE Designer gives small set of functional tests – augment with structural tests to boost coverage to 98+ % 2003 Agrawal: Digital Test and DFT

Random-Pattern Generation Flow chart for method Use to get tests for 60-80% of faults, then switch to D-algorithm or other ATPG for rest 2003 Agrawal: Digital Test and DFT

Path Sensitization Method Circuit Example Fault Activation Fault Propagation Line Justification 2003 Agrawal: Digital Test and DFT

Path Sensitization Method Circuit Example Try path f – h – k – L blocked at j, since there is no way to justify the 1 on i 1 D D D D 1 D 1 1 2003 Agrawal: Digital Test and DFT

Path Sensitization Method Circuit Example Try simultaneous paths f – h – k – L and g – i – j – k – L blocked at k because D-frontier (chain of D or D) disappears 1 D D 1 1 D D D 2003 Agrawal: Digital Test and DFT

Path Sensitization Method Circuit Example Final try: path g – i – j – k – L – test found! D D 1 D D D 1 1 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Sequential Circuits A sequential circuit has memory in addition to combinational logic. Test for a fault in a sequential circuit is a sequence of vectors, which Initializes the circuit to a known state Activates the fault, and Propagates the fault effect to a primary output Methods of sequential circuit ATPG Time-frame expansion methods Simulation-based methods 2003 Agrawal: Digital Test and DFT

Concept of Time-Frames If the test sequence for a single stuck-at fault contains n vectors, Replicate combinational logic block n times Place fault in each block Generate a test for the multiple stuck-at fault using combinational ATPG with 9-valued logic Vector -n+1 Vector -1 Vector 0 Fault Unknown or given Init. state State variables Next state Time- frame -n+1 Time- frame -1 Time- frame Comb. block PO -n+1 PO -1 PO 0 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT An Example of Seq. ATPG FF1 B A FF2 s-a-1 2003 Agrawal: Digital Test and DFT

Nine-Valued Logic (Muth) 0,1, 1/0, 0/1, 1/X, 0/X, X/0, X/1, X A X s-a-1 s-a-1 0/1 X/1 X 0/X 0/X FF1 FF1 X 0/1 X/1 FF2 FF2 B X B 0/1 Time-frame -1 Time-frame 0 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Seq. ATPG Results s1423 s5378 s35932 Total faults 1,515 4,603 39,094 Detected faults 1,414 3,639 35,100 Fault coverage 93.3% 79.1% 89.8% Test vectors 3,943 11,571 257 CPU time 1.3 hrs. 37.8 hrs. 10.2 hrs. HP J200 256MB Ref.: M. S. Hsiao, E. M. Rudnick and J. H. Patel, “Dynamic State Traversal for Sequential Circuit Test Generation,” ACM Trans. on Design Automation of Electronic Systems (TODAES), vol. 5, no. 3, July 2000. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Summary: ATPG Combinational ATPG is significantly more efficient than sequential ATPG. Combinational ATPG tools are commercially available. Design for testability is essential if the circuit is large (million or more gates) and high fault coverage (~95%) is required. 2003 Agrawal: Digital Test and DFT

Design for Testability 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Definition Design for testability (DFT) refers to those design techniques that make test generation and test application cost-effective. DFT methods for digital circuits: Ad-hoc methods Structured methods: Scan Partial Scan Built-in self-test (BIST) Boundary scan DFT method for mixed-signal circuits: Analog test bus 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Ad-Hoc DFT Methods Good design practices learnt through experience are used as guidelines: Avoid asynchronous (unclocked) feedback. Make flip-flops initializable. Avoid redundant gates. Avoid large fanin gates. Provide test control for difficult-to-control signals. Avoid gated clocks. . . . Consider ATE requirements (tristates, etc.) Design reviews conducted by experts or design auditing tools. Disadvantages of ad-hoc DFT methods: Experts and tools not always available. Test generation is often manual with no guarantee of high fault coverage. Design iterations may be necessary. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Scan Design Circuit is designed using pre-specified design rules. Test structure (hardware) is added to the verified design: Add a test control (TC) primary input. Replace flip-flops by scan flip-flops (SFF) and connect to form one or more shift registers in the test mode. Make input/output of each scan shift register controllable/observable from PI/PO. Use combinational ATPG to obtain tests for all testable faults in the combinational logic. Add shift register tests and convert ATPG tests into scan sequences for use in manufacturing test. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Scan Design Rules Use only clocked D-type of flip-flops for all state variables. At least one PI pin must be available for test; more pins, if available, can be used. All clocks must be controlled from PIs. Clocks must not feed data inputs of flip-flops. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Scan Flip-Flop (SFF) D Master latch Slave latch TC Q Logic overhead MUX Q SD CK D flip-flop Master open CK Slave open t Normal mode, D selected Scan mode, SD selected TC t 2003 Agrawal: Digital Test and DFT

Level-Sensitive Scan-Design Flip-Flop (LSSD-SFF) Master latch Slave latch D Q MCK Q SCK D flip-flop SD MCK Normal mode Logic overhead TCK MCK TCK Scan mode TCK SCK t 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Adding Scan Structure PI PO SFF SCANOUT Combinational logic SFF SFF TC or TCK Not shown: CK or MCK/SCK feed all SFFs. SCANIN 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Comb. Test Vectors I1 I2 O1 O2 PI PO Combinational logic SCANIN TC SCANOUT S1 S2 N1 N2 Next state Present state 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Testing Scan Register Scan register must be tested prior to application of scan test sequences. A shift sequence 00110011 . . . of length nsff+4 in scan mode (TC=0) produces 00, 01, 11 and 10 transitions in all flip-flops and observes the result at SCANOUT output. Total scan test length: (ncomb + 2) nsff + ncomb + 4 clock periods. Example: 2,000 scan flip-flops, 500 comb. vectors, total scan test length ~ 106 clocks. Multiple scan registers reduce test length. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Scan Overheads IO pins: One pin necessary. Area overhead: Gate overhead = [4 nsff/(ng+10nff)] x 100%, where ng = comb. gates; nff = flip-flops; Example – ng = 100k gates, nff = 2k flip-flops, overhead = 6.7%. More accurate estimate must consider scan wiring and layout area. Performance overhead: Multiplexer delay added in combinational path; approx. two gate-delays. Flip-flop output loading due to one additional fanout; approx. 5-6%. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT ATPG Example: S5378 Original 2,781 179 0.0% 4,603 35/49 70.0% 70.9% 5,533 s 414 Full-scan 2,781 179 15.66% 4,603 214/228 99.1% 100.0% 5 s 585 105,662 Number of combinational gates Number of non-scan flip-flops (10 gates each) Number of scan flip-flops (14 gates each) Gate overhead Number of faults PI/PO for ATPG Fault coverage Fault efficiency CPU time on SUN Ultra II, 200MHz processor Number of ATPG vectors Scan sequence length 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Summary: Scan Design Scan is the most popular DFT technique: Rule-based design Automated DFT hardware insertion Combinational ATPG Advantages: Design automation High fault coverage; helpful in diagnosis Hierarchical – scan-testable modules are easily combined into large scan-testable systems Moderate area (~10%) and speed (~5%) overheads Disadvantages: Large test data volume and long test time Basically a slow speed (DC) test 2003 Agrawal: Digital Test and DFT

Built-In Self-Test (BIST) 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT BIST Process Test controller – Hardware that activates self-test simultaneously on all PCBs Each board controller activates parallel chip BIST Diagnosis effective only if very high fault coverage 2003 Agrawal: Digital Test and DFT

Example External XOR LFSR Characteristic polynomial f (x) = 1 + x + x3 (read taps from right to left) 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Definitions Aliasing – Due to information loss, signatures of good and some bad machines match Compaction – Drastically reduce # bits in original circuit response – lose information Compression – Reduce # bits in original circuit response – no information loss – fully invertible (can get back original response) Signature analysis – Compact good machine response into good machine signature. Actual signature generated during testing, and compared with good machine signature 2003 Agrawal: Digital Test and DFT

Example Modular LFSR Response Compacter LFSR seed value is “00000” 2003 Agrawal: Digital Test and DFT

Multiple-Input Signature Register (MISR) Problem with ordinary LFSR response compacter: Too much hardware if one of these is put on each primary output (PO) Solution: MISR – compacts all outputs into one LFSR Works because LFSR is linear – obeys superposition principle Superimpose all responses in one LFSR – final remainder is XOR sum of remainders of polynomial divisions of each PO by the characteristic polynomial 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Modular MISR Example 2003 Agrawal: Digital Test and DFT

Built-in Logic Block Observer (BILBO) Combined functionality of D flip-flop, pattern generator, response compacter, & scan chain Reset all FFs to 0 by scanning in zeros 2003 Agrawal: Digital Test and DFT

Circuit Initialization Full-scan BIST – shift in scan chain seed before starting BIST Partial-scan BIST – critical to initialize all FFs before BIST starts Otherwise we clock X’s into MISR and signature is not unique and not repeatable Discover initialization problems by: Modeling all BIST hardware Setting all FFs to X’s Running logic simulation of CUT with BIST hardware 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Summary: BIST LFSR pattern generator and MISR response compacter – preferred BIST methods BIST has overheads: test controller, extra circuit delay, Input MUX, pattern generator, response compacter, DFT to initialize circuit & test the test hardware BIST benefits: At-speed testing for delay & stuck-at faults Drastic ATE cost reduction Field test capability Faster diagnosis during system test Less effort to design testing process Shorter test application times 2003 Agrawal: Digital Test and DFT

IEEE 1149.1 Boundary Scan Standard 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT System Test Logic 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Serial Board / MCM Scan 2003 Agrawal: Digital Test and DFT

Parallel Board / MCM Scan 2003 Agrawal: Digital Test and DFT

Tap Controller Signals Test Access Port (TAP) includes these signals: Test Clock Input (TCK) -- Clock for test logic Can run at different rate from system clock Test Mode Select (TMS) -- Switches system from functional to test mode Test Data Input (TDI) -- Accepts serial test data and instructions -- used to shift in vectors or one of many test instructions Test Data Output (TDO) -- Serially shifts out test results captured in boundary scan chain (or device ID or other internal registers) Test Reset (TRST) -- Optional asynchronous TAP controller reset 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Summary: Bound. Scan Functional test: verify system hardware, software, function and performance; pass/fail test with limited diagnosis; high (~100%) software coverage metrics; low (~70%) structural fault coverage. Diagnostic test: High structural coverage; high diagnostic resolution; procedures use fault dictionary or diagnostic tree. SOC design for testability: Partition SOC into blocks of logic, memory and analog circuitry, often on architectural boundaries. Provide external or built-in tests for blocks. Provide test access via boundary scan and/or analog test bus. Develop interconnect tests and system functional tests. Develop diagnostic procedures. 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT IDDQ Test 2003 Agrawal: Digital Test and DFT

Basic Principle of IDDQ Testing Measure IDDQ current through Vss bus 2003 Agrawal: Digital Test and DFT

Capacitive Coupling of Floating Gates Cpb – capacitance from poly to bulk Cmp – overlapped metal wire to poly Floating gate voltage depends on capacitances and node voltages If nFET and pFET get enough gate voltage to turn them on, then IDDQ test detects this defect K is the transistor gain 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Sematech Results Test process: Wafer Test Package Test Burn-In & Retest Characterize & Failure Analysis Data for devices failing some, but not all, tests. pass fail 14 6 52 1 36 1463 34 13 1251 7 8 Scan-based Stuck-at IDDQ (5 mA limit) Functional Scan-based delay 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT Summary: IDDQ Test IDDQ tests improve reliability, find defects causing: Delay, bridging, weak faults Chips damaged by electro-static discharge No natural breakpoint for current threshold Get continuous distribution – bimodal would be better Conclusion: now need stuck-fault, IDDQ, and delay fault testing combined Still uncertain whether IDDQ tests will remain useful as chip feature sizes shrink further 2003 Agrawal: Digital Test and DFT

Agrawal: Digital Test and DFT References M.L. Bushnell and V. D. Agrawal, Essentials of Electronic Testing for Digital, Memory and Mixed-Signal VLSI Circuits, Boston: Kluwer Academic Publishers, 2000, ISBN 0-7923-7991-8. For the material on a course taught by the authors at Rutgers University, and a complete bibliography from the above book, see website: http://cm.bell-labs.com/cm/cs/who/va 2003 Agrawal: Digital Test and DFT