Net Diagnosis using Stuck-at and Transition Fault Models Master’s Defense Lixing Zhao Thesis Advisor: Dr. Vishwani D. Agrawal Thesis Committee: Dr. Adit Singh and Dr. Victor P. Nelson Department of Electrical and Computer Engineering Auburn University, AL 36849 USA Oct. 26, 2011 Lixing's MS Defense

Outline Proposed Fault Filtering System Proposed Fault Ranking System Motivation Background Problem Statement Contributions Proposed Fault Filtering System Proposed Fault Ranking System Proposed Net Ranking System Conclusion Oct. 26, 2011 Lixing's MS Defense Lixing’s MS Defense

Motivation Due to high logic density of modern VLSI design and manufacturing, chips on the first round of tape-out often suffer a relatively low yield that may be unacceptable. Fault diagnosis can bring the yield up in later manufacturing rounds by indentifying the possible causes of defect in earlier tape-outs. Net fault diagnosis is an important area of fault diagnosis. Because of the large routing area of modern VLSI devices, the routing interconnection nets are more vulnerable to certain defects. In this work, we try to provide an effective method on solving the net-diagnosis problem. Oct. 26, 2011 Lixing's MS Defense

Outline Proposed Fault Filtering System Proposed Fault Ranking System Motivation Background Problem Statement Contributions Proposed Fault Filtering System Proposed Fault Ranking System Proposed Net Ranking System Conclusion Oct. 26, 2011 Lixing's MS Defense

How does Fault Diagnosis Work? Defective Circuit Circuit Responses Test Vectors Circuit Net-list Compare Expected Responses Possible Defect Locations Diagnosis Algorithm Oct. 26, 2011 Lixing's MS Defense

Circuit Under Diagnosis The Circuit Under Diagnosis (CUD) can be classified into two groups: Combinational Circuits: Sequential Circuits: Oct. 26, 2011 Lixing's MS Defense

Diagnosis Pattern Random Pattern: Randomly or Pseudo Randomly Generated Computer program or Pattern generator (e.g., LFSR) N-Detect Pattern: Each fault is detected by at least N different Patterns ATPG-based Fault-Model-Based Patterns: Patterns used for diagnosing faults based on certain fault model Using certain generating algorithm and ATPG Yu Zhang and Vishwani D. Agrawal, "A Dianostic Test Generation System," in Proc. International Test Conf., Nov.2010, pp.1-9. Yu Zhang and Vishwani D. Agrawal, "Reduced Complexity Test Generation Algorithms for Transition Fault Diagnosis", International Conf. on Computer Design, Oct. 2011. pp. 96-101. Oct. 26, 2011 Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

Fault Models Fault model is an abstraction of the real defect in chip and different fault models are used to handle different types of defects in fault diagnosis. The types of fault model that can be used on a net: Stuck-at fault Transition fault Bridging fault Open fault Oct. 26, 2011 Lixing's MS Defense

Open Fault Interconnect Open: undesired breaks and electrical discontinuities on interconnection line. Resistive Open: narrow crack Modeled as transition delay fault Oct. 26, 2011 Lixing's MS Defense

Complete Open: wide crack The coupling capacitors between the floating node and the supply and ground. The drain voltage of the driven gates. The effects from surrounding lines. Oct. 26, 2011 Lixing's MS Defense

Net Structure A net means a connection metal wire in the circuit. Oct. 26, 2011 Lixing's MS Defense

Previous Works on Multiple Faults Diagnosis Single-Fault-Simulation(TFS)-Based Multiple-Faults-Simulation(MFS)-Based Single-Location-AT-a-Time(SLAT)-Based Region-Model-Based Oct. 26, 2011 Lixing's MS Defense

SLAT Oct. 26, 2011 Lixing's MS Defense

X-Region Oct. 26, 2011 Lixing's MS Defense

Diagnosis Strategies Cause-Effect method diagnosis faults by comparing the fault simulation results with the CUD response. Traditional Simulation More information available but more costs. Effect-Cause method diagnosis faults by tracing from erroneous primary outputs. Back-trace simulation Lost some information but fewer costs. Oct. 26, 2011 Lixing's MS Defense

OUTLINE Proposed Fault Filtering System Proposed Fault Ranking System Motivation Background Problem Statement Contributions Proposed Fault Filtering System Proposed Fault Ranking System Proposed Net Ranking System Conclusion Oct. 26, 2011 Lixing's MS Defense

Problem Statement Given the failing response of CUD Failing Pattern Index Index of Erroneous Primary Outputs (EPO) Given the net-list of CUD Verilog file Find out locations of faulty nets with certain defects. Oct. 26, 2011 Lixing's MS Defense

OUTLINE Proposed Fault Filtering System Proposed Fault Ranking System Motivation Background Problem Statement Contributions Proposed Fault Filtering System Proposed Fault Ranking System Proposed Net Ranking System Conclusion Oct. 26, 2011 Lixing's MS Defense

Proposed Fault Filtering System Count Assignment: A Count is a value we assign to each fault candidate under certain measurement method. Contribution: A more balanced count assignment method for fault candidates filtering. The Count we use in our filtering system is a ratio-count. Count = Oct. 26, 2011 Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

Failing Pattern Index Matching DEF1:The union of all the failing pattern index from the single fault simulation of a fault candidate is defined as the Detectable Pattern Set (DPS) of this fault under the test. DEF2:The union of all the failing pattern index of the observed CUD response is defined as the Failing Pattern Set (FPS) of the test. DEF3:The shared part between the DPS of a fault candidate and the FPS of CUD is called the Shared Pattern Set (SPS) of this candidate. Oct. 26, 2011 Lixing's MS Defense

THEOREM: If the CUD is a circuit with multiple faults and we assume that all the multiple faults in the circuit will not totally cancel each other on the primary outputs, then the DPS of any one of the multiple faults in the circuit should be a subset of FPS of the test, in other words, the SPS of the fault candidate equals to its DPS. INTUITIVE ASSUPTION: The percentage of SPS takes in DPS of a fault represents the possibility that this fault be a real one in CUD. Count = Oct. 26, 2011 Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

FPIM with EPO-Hitting DEF: Under the same test pattern, if the affected primary outputs of a candidate fault simulation shares at least one erroneous output with the faulty response of CUD, then we say that this fault candidate can 'hit' the EPO under this pattern and this pattern is called a Hit-Pattern of this candidate. Count = Oct. 26, 2011 Lixing's MS Defense

EPO-Matching DEF1: A Pattern-EPO-Pair (PEP) is a pair of failing pattern number and an EPO associated with it. Like [P2, PO1], which indicates under pattern P2, an error is observed on PO1. PEP could be used to either represents the faulty response of CUD testing or the fault simulation results of fault candidate. DEF2: The union of all the PEPs from CUD testing is called PEP-Set-of-CUD (PEPSC) and the union of the PEPs under all the patterns in SPS of a fault candidate is called the PEP-Set-of-Fault (PEPSF). The shared part of PEPSC of a fault candidate with PEPSF of CUD is called Shared-PEP-Set (SPEPS) of this fault candidate. Oct. 26, 2011 Lixing's MS Defense

THEOREM: If CUD is a circuit with multiple faults and we assume that there is no cancelling effect among these faults, then the PEPSF of a fault candidate in single fault simulation should be the subset of of CUD and the SPEPS of the fault candidate should equal to its PEPSF. INTUITIVE ASSUPTION: The percentage SPEPS taking in PEPSF of a fault candidate indicates the possibility that this fault be a real one in CUD. Count = Oct. 26, 2011 Lixing's MS Defense

Count of Fault1: 3/3=1 Count of Fault2: 3/4 = 0.75 Lixing's MS Defense Oct. 26, 2011 Lixing's MS Defense

For each step, we will set one threshold value to filter the unrelated fault candidates out. These threshold values depend on the our assumption on fault density of CUD. Oct. 26, 2011 Lixing's MS Defense

Filtering Results Circuit # of Total Faults Reduction Rate Survival Rate C432 524 0.77 0.975 C880 942 0.97 0.96 C1355 1574 0.75 C1908 1879 0.85 0.95 C2670 2747 0.925 C3540 3428 0.965 C6288 7744 0.933 C7552 7419 0.992 Oct. 26, 2011 Lixing's MS Defense

OUTLINE Proposed Fault Filtering System Proposed Fault Ranking System Motivation Background Problem Statement Contributions Proposed Fault Filtering System Proposed Fault Ranking System Proposed Net Ranking System Conclusion Oct. 26, 2011 Lixing's MS Defense

Candidate Ranking System After getting a smaller list of fault candidates from filtering stage, we need to rank the fault candidates so that we can have a better diagnosis resolution. A structure called EPO-Tree is used in our work. Oct. 26, 2011 Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

Branch Ranking in EPO-Trees with Same Branch Combination Observation: The activation situations are sometimes similar under certain test patterns, which means these patterns can activate same set of injected faults in the CUD and the observed EPO combinations from the CUD are the same. Intuitive Assumption: Assuming we have a circuit with large enough number of primary outputs, when the failing outputs combinations are the same under different test patterns, because it is not very easy to repeat the same combinations for different injected faults in CUD, it is possible that the cause of these failures are the same. If we can find shared set of leaves between the corresponding branches in these EPO-Trees, then these shared faults are more possible than other faults in branch to be the real faults. Oct. 26, 2011 Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

Branch Ranking with Counts from Reduction Stage Branch ranking procedure we used in step two, three and five. The candidates in each branch have already had an initial rank from previous stage, now what we have to do is to utilize the counts of each fault got from reduction stage to rank the candidates within each group. Oct. 26, 2011 Lixing's MS Defense

Branch Ranking with Leaves Count in Each EPO-Tree Rule: If several fault candidates still have the same rank after previous ranking steps, then we assume that the ones with more leaves in the EPO-Tree have more chance to be real faults in CUD, because it is much easier to activate just one or two faults than many faults together to cause the same effects. Oct. 26, 2011 Lixing's MS Defense

Final Fault Ranking We rank the fault candidates by considering the best rank they have among all the branches in all EPO-Trees. A Top-Single-Fault is a single fault that has top rank in a branch. This kind of faults are the most suspicious fault candidates to us in diagnosis. Because we have applied many constraints in branch ranking, the earlier the TSF comes out, the more suspicious it seemed to us. Oct. 26, 2011 Lixing's MS Defense

Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

Wang’s work(1 stuck-at) Wang’s work(2 stuck-at) Experimental Results Cir Our Work(1 Stuck-at) Wang’s work(1 stuck-at) Dia FHR RES T(s) Res c2670 1.0 6.4 1.27 1.3 0.01 c3540 0.5 1.2 1.5 c6288 0.6 1.1 c7552 1.15 1.6 Cir Our Work(2 Stuck-at) Wang’s work(2 stuck-at) Dia FHR RES T(s) Res c2670 0.97 1.0 2.0 8 1.35 0.05 c3540 0.95 0.6 1.2 1.7 0.06 c6288 0.99 1 1.28 0.2 c7552 0.93 0.925 1.25 Z. Wang, M. Marek-Sadowska, and J. Rajski, "Analysis and methodology for multiple-fault diagnosis,” IEEE Tran on CAD of Integrated Circuits and Systems, March 2006, vol. 25, pp. 558-576. Oct. 26, 2011 Lixing's MS Defense

Wang’s work(3 stuck-at) Wang’s work(4 stuck-at) Cir Our Work(3 Stuck-at) Wang’s work(3 stuck-at) Dia FHR RES T(s) Res c2670 0.94 1.0 2.0 13 0.925 1.35 2.6 0.1 c3540 0.7 0.92 1.15 2.4 c6288 0.95 2.7 0.93 2.5 0.5 c7552 0.90 1.04 2.9 1.2 2.3 0.25 Cir Our Work(4 stuck-at) Wang’s work(4 stuck-at) Dia FHR RES T(s) Res c2670 0.89 1.06 2.0 17 0.92 1.3 2.6 0.2 c3540 0.91 1.0 1.8 1.25 2.5 c6288 1.02 5.7 0.82 1.15 2.8 0.8 c7552 0.88 1.1 3.2 1.2 2.4 0.5 Oct. 26, 2011 Lixing's MS Defense

Fault List Extension Before we start handling the net diagnosis work, we need to first extend the collapsed faults to uncollapsed faults. Oct. 26, 2011 Lixing's MS Defense

From the net-list of the circuit, we can get the corresponding net for each fault. Then each group of equivalent faults can be transformed into a set of nets. Oct. 26, 2011 Lixing's MS Defense

OUTLINE Proposed Fault Filtering System Proposed Fault Ranking System Motivation Background Problem Statement Contributions Proposed Fault Filtering System Proposed Fault Ranking System Proposed Net Ranking System Conclusion Oct. 26, 2011 Lixing's MS Defense

Net Ranking First, we build a net pool, which will include all the net candidates of each rank group. Final net candidate list includes two parts: The nets which we can find more than two members in the net pool. The nets which can only be found once in the net pool. Nets’ ranking are based on the group's rank they derived from. Oct. 26, 2011 Lixing's MS Defense

Oct. 26, 2011 Lixing's MS Defense

Experimental Results For each fault model and each benchmark circuit, we randomly constructed 20-50 faulty circuits. For each injected net fault, we randomly selected 2-4 fault sites which could be either the stem or the branches of the net. For stuck-at model, we injected one single stuck-at fault on each fault site and for transition net fault we injected a D-flip-flop on each fault site to perform transition delay behavior. Oct. 26, 2011 Lixing's MS Defense

One Net Fault(Stuck-at) Two Net Fault(Stuck-at) Dia FHR Res T c432 1.0 Cir One Net Fault(Stuck-at) Two Net Fault(Stuck-at) Dia FHR Res T c432 1.0 1.1 2.0 0.1 0.98 1.2 3.0 0.2 c880 c1355 0.75 2.6 5.0 16 c1908 0.92 1.4 7.5 0.86 1.3 13 c2670 7.4 0.95 1.14 4.0 12 c3540 1.04 0.5 0.96 0.7 c6288 3 0.9 1.06 4 c7552 11 Oct. 26, 2011 Lixing's MS Defense

One Net Fault(Transition) Two Net Fault(Transition) Dia FHR Res T c432 Cir One Net Fault(Transition) Two Net Fault(Transition) Dia FHR Res T c432 1.0 1.05 2.0 0.48 0.9 1.2 3.0 0.7 c880 0.8 1.3 2.3 c1355 0.86 13 c1908 0.96 7.2 0.93 1.4 35 c2670 1.16 0.97 1.06 4.6 c3540 0.98 1.7 0.95 1.1 c6288 1.08 2.8 0.92 c7552 7.5 13.1 Oct. 26, 2011 Lixing's MS Defense

OUTLINE Proposed Fault Filtering System Proposed Fault Ranking System Motivation Background Problem Statement Contributions Proposed Fault Filtering System Proposed Fault Ranking System Proposed Net Ranking System Conclusion Oct. 26, 2011 Lixing's MS Defense

Advantages Utilizing only single fault simulation, which avoids the problem of exponential searching space in multiple-fault-simulation-based works. No requirement for the ability of testing pattern to trigger single fault at a time. A balanced candidate filtering system which can effectively reduce the number of fault candidates and to some extent tolerate the non-stuck-at behavior caused by other types of faults. A candidate ranking system with high First Hit Rank(FHR), diagnosis resolution and diagnosability. Suitable for diagnosing multiple types of faults. Oct. 26, 2011 Lixing's MS Defense

Conclusion Traditional gate faults are closely related to the fault models and not necessarily to physical defects. Therefore, from a practical viewpoint it makes sense to diagnose a faulty net on a VLSI chip than to locate a `modeled' fault. Our use of stuck-at and transition faults models is for a practical reason, i.e., availability of tools for test generation and fault simulation. These models are used only for the possibility of analysis they offer. In identifying faulty nets no assumption is made about the actual fault on them except that those nets `may' have caused the observed and simulated errors. The fault models may, or may not be, used as suggestions. We verified our work with the injected multiple-faults. In the future, arbitrary defects such as bridges, opens, short, etc., should be examined to evaluate the presented diagnosis algorithms. Oct. 26, 2011 Lixing's MS Defense

References Yu Zhang and Vishwani D. Agrawal, “A Dianostic Test Generation System,” In Proc. International Test Conf., 2010, pp.1-9. Yu Zhang and Vishwani D. Agrawal, “Reduced Complexity Test Generation Algorithms for Transition Fault Diagnosis,” In Proc. International Conf. on Computer Design, 2011, pp. 96-101. N. Sridhar and M.S. Hsiao, “On Efficient Error Diagnosis of Digital Circuits,” In Proc. International Test Conference, 2001, pp. 678 - 687. S.M. Reddy, H. Tang, I. Pomeranz, S. Kajihara and K. Kinoshita, “On Testing of Interconnect Open Defects in Combinational Logic Circuits with Stems of Large Fanout,” In Proc. Intl Test Conf. , 2002, pp. 83-87. Z. Wang, M.Sadowska, and J. Rajski, “Analysis and Methodology for Multiple-fault Diagnosis,” IEEE Tran on CAD of Integrated Circuits and Systems, March 2006, vol. 25, pp. 558-576. S. Venkataraman and S. B. Drummonds, “Poirot: Applications of a Logic Fault Diagnosis Tool,” IEEE Design and Test of Computers, Jan. 2001, pp. 19-29. J. Segura and C. F. Hawkins, “CMOS Electronics: how it works, how it fails,” Wiley- IEEE, Apr. 2004. Oct. 26, 2011 Lixing's MS Defense

Thank You . . . Oct. 26, 2011 Lixing's MS Defense

Questions Oct. 26, 2011 Lixing's MS Defense