Digital Design Obsolescence Military Aerospace and High Reliability

Digital Design Obsolescence Military, Aerospace, and High Reliability IC Manufacturer John O’Boyle For MAPLD September 2005 O'Boyle 1 MAPLD 2005/P 1023

Defense Programs Still Need OLD ICs • 30 Year Old ICs Are Still in Use in many modern High Reliability, Military, and Aerospace applications. • Combining New Technologies and older devices leave Mil/Aero OEMs challenged with IC sourcing due to obsolescence. • The Fabrication of Obsolete ICs Is Not Attractive due to low returns and matching original designs. O'Boyle 2 MAPLD 2005/P 1023

Issue : Diminishing Supply • In Some Cases the Parts Just Vanish: – Take, for example, the Dual RS-422 Line Drivers to the right – National Semi unilaterally discontinued the supply of these devices on April 21, 2005. – Why? Because they simply ran out, no close monitoring of the supply – This means even the best managed programs may be vulnerable. O'Boyle 3 MAPLD 2005/P 1023

TODAY’s Key Challenge How Does a Mil/Aero OEM Obtain Reliable, Accurate Reproduction of Older Parts? or How Do They Entice the IC Foundry to Build Such Replacement Parts? O'Boyle 4 MAPLD 2005/P 1023

Factors for Consideration • Buy Entire Remaining Inventory; But that’s very expensive and many various Gov’t regs limit requisition quantities. – And, as a corollary to the RS-422 example, that is still no guarantee; demand can outstrip supply. • Use Commercial Parts From the Beginning; But they, too, are diminishing and are not suitable in all applications. • So, do we look to the foundry for a solution? Let’s See … O'Boyle 5 MAPLD 2005/P 1023

1. Foundry : Low Volumes A Fundamental Disconnect • An Illustration – Teledesic (the early days) – Almost 1000 satellites (Close enough for this illustration) – Assume 100 “Identical” parts per satellite, balance are other hi-rel. – Build them all in one year (Not realistic, but suitable for this example). – Spares at 100% of original build. – Complex die, Estimate die size 5 by 6 mm. – Technology: 0. 25 Micron on 8 -inch wafers. – Total fab, assembly, test yield = 85%. O'Boyle 6 MAPLD 2005/P 1023

Low Volumes = Low Profitability for IC Mfg This is Reality • 1000 x 100 = 100 k devices • Plus 100% spares = 200 k • Total die needed: 200 k/85% = 236 k round to 250 k die • Gross die per wafer 1000 • Total 250 k/1000 = 250 wafers • In 1996 top 10 IDMs (Integrated Device Mfr. ) were 20 million wafers per year • 250/20 million = 0. 00125 % • Bottom line: Volume is insignificant for the foundries O'Boyle 7 MAPLD 2005/P 1023

2. Lack of Process Knowledge • Modern designers use tools with IP embedded – they place blocks with 100 s of transistors, or more. – Plus, design rules prohibit changes. • Important when designing a complex digital device or the time to complete would be prohibitive doing “Stick” designs. • Designers today enjoy no real process knowledge – No understanding of the nuances of the process used to make their design at the foundry. O'Boyle 8 MAPLD 2005/P 1023

“Lack” – is a Real Gap An Example: • Temp compensated bias driver – As temp changed, reference voltages A, B, and C remain unchanged. • Why? – The process had very linear negative TC for VBE which was used in a ratio between D 3 and Q 6 to afford ideal positive compensation. • A new designer tried to “Copy” the part but did not understand the process so the part failed to work. O'Boyle 9 MAPLD 2005/P 1023

3. Foundry : Economic Imperatives • Wafer Throughput and Yield – – – • Large scale manufacturing economics drive the foundries and fabs. The fixed costs are very high and short term variable costs are significant, too. The factories must produce many wafers just to reach breakeven. Cardinal Rules: 1. “Fill the Fab” 2. Minimize process variations: wafers out/wafers started 100% (or As Close As Possible “Cut the Scrap”) O'Boyle 10 MAPLD 2005/P 1023

Incredibly High Investments • Over 68 foundries listed by FSA (Fabless Semiconductor Association) today, not counting firms like Toshiba (not listed). • Today a 130/90 nm Fab Costs $3 to $4 Billion. Plus expendables. • Opportunity cost related to stopping a running fab to insert 250 wafers for an annual buy is expensive. – This is applies to most fabs, 12 -inch, 8 -inch and even 6 inch. O'Boyle 11 MAPLD 2005/P 1023

Breakeven Is High • Figure 1 (8 inch 0. 18 micron fab): – At different wafer prices the monthly breakeven moves from $15 Million and 15 k wafers for $1 k Per wafer to $16 Million for 20 k wafers at $800 each. O'Boyle 12 MAPLD 2005/P 1023

Breakeven is Very High • Figure 2 (12 inch 90 nm fab): – At $2500 per wafer the monthly breakeven Is $40 Million for 17 k wafers and at $1500 breakeven will not be achieved until the variable costs come down. Yikes! O'Boyle 13 MAPLD 2005/P 1023

4. Foundry : Scarce Expertise • Today’s Obsolete Device Designer relies on modern tools and experience and knowledge about process – a True Artisan. • Gone Are the Days of Pencil & paper and Karnaugh maps (Min-sums); Mylar Grids with Mylar transistors and hand-drawn resistors; “Digitizers” and Rubyliths; 500 x cameras that floated on Hg; chrome masters and glass plate masks. O'Boyle 14 MAPLD 2005/P 1023

Tackling Obsolescence Today – A Few Solutions • Size Does Matter – Hi-Rel volumes too small to be attractive. So think SMALL • Emulate – Works when no other solutions are available. • Create – NEW APPROACH; Much closer to original and more reasonable in investment. O'Boyle 15 MAPLD 2005/P 1023

1. Solution – Size Does Matter • The Large Foundries (TSMC, UMC, SMIC, etc. ) are out of reach to small Hi-Rel OEMs. • Small “Research Oriented” Foundries (Typically under 10, 000 wafers a year, sometimes much lower) will still run special lots. – Caution: Their processes are not as well controlled as modern flows, but they are better than anything else available. O'Boyle 16 MAPLD 2005/P 1023

2. Solution – Emulate … • There a couple of approaches available which allow a design team to emulate an obsolete part, right down to the timing delays. • Works well for logic, the analog function is still in question, but they’re working on that too. • There available programmable approaches. • May be a possible low volume obsolete parts replacement. O'Boyle 17 MAPLD 2005/P 1023

3. NEW APPROACH: The Multi-Project Die (“MPD”) • Amortize Mask Tool Costs Across Several Parts – Derive several different options from “MPW” Die – Metal mask programmable – Allows wafer hold at metal and patterning to meet orders – Quick Turns • Higher WSM (Wafer Starts per Month) figures to foundry partner • Not constrained by Max GDPW (Gross Die Per Wafer) • Flexible Family Sets; Memories, sequential and combinatorial logic – 34 different parts on first MPD. O'Boyle 18 MAPLD 2005/P 1023

Options for MPD • I/Os: – TTL Totem Pole – DTL – Multiple I/Os • PROM – Metal Mask – Core covers major and Minor densities in range (S, M, L) – Fusible links next • Foundry holds average of 24 wafers at metal. When down to 12, they start another 24. O'Boyle Four Peripheral Drivers, One Wafer: QP 1631, QP 1632, QP 1633 and QP 1634 19 MAPLD 2005/P 1023

Metal Options (OP 1) Note, One Connection Scheme in OP 1 O'Boyle 20 MAPLD 2005/P 1023

Metal Options (OP 2) And Another Scheme in OP 2 O'Boyle 21 MAPLD 2005/P 1023

Summary • Economies of scale are opposite between a foundry and an obsolete device maker. – Partnering with the right manufacturing partner is key • An obsolete device designer needs process knowledge to tailor the design to take advantage of “anomalies”. • The obsolete designer must find creative ways to fabricate parts: – Focus on what is important to achieve performance – Target smaller foundries – Adapt designs/layout(s) for flexibility in die size while keeping costs within reason. O'Boyle 22 MAPLD 2005/P 1023