BY JOHN H. O’KUMABY JOHN H. O’KUMA AUGUST 20-25, 2000AUGUST 20-25, 2000
INNOVATIVERADIATION TOLERANCEDMSMS MANAGEMENT
INNOVATIVERADIATION TOLERANCEDMSMS MANAGEMENT
DMSMSConference
2000
JUNE_6_00
OUTLINEOUTLINE
=DMSMS=Background=What Is RTA?=RTA DMSMS=Defining the Problem=Solution What is RTASSC?
Essential Element - Partnerships RTA’s DMSMS And RT DMSMS Approach
RTA DMSMS ElementsSolutions ToolsRTASSC ProcessRTA Certification EvolutionMonitoring and Tracking System
=Summary=Conclusion
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BACKGROUNDBACKGROUND PIECE-PART FACTS PIECE-PART FACTS
Basically, Every Type Of QML Device And An Ever Increasing Number Of COTS DevicesAre Used In Military Platforms, Systems And Equipment.
Most Of These Same Devices Are Classified as Hardness Critical Items (HCIs) and Used InNuclear Survivable Platforms, Systems And Equipment; However,u < 2% Of All HCIs Are Radiation Hardened/Tolerant and Guaranteed By
the Device Manufactureru > 98% Of All HCIs Are Classified as Radiation Tolerance (RT) and
Evaluated By An Independent Radiation Test Facility.In Contrast; HCIs for Most Space and Missile Platforms, Systems and Equipment,
u > 60% Of All HCIs Are Radiation Hardened/Tolerant and Guaranteed By the Device Manufacturer
u < 40% Of All HCIs Are Classified as Radiation Tolerance (RT) and Evaluated By An Independent Radiation Test Facility.
u This Ratio is Shifting Towards Greater Usage of RT Devices
All RT Devices are DMSMS Candidates
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BACKGROUNDBACKGROUNDRADIATION TOLERANCE FACTORRADIATION TOLERANCE FACTOR
Basically, Every Type Of QML Device And An Ever Increasing Number Of COTS Devices AreUsed In Military Platforms, Systems And Equipments That are Nuclear Survivable
Each RTA Device Is RT Certified, Usually Through A Detailed Characterization-Test-Qualification- (CTQ) Process
CTQ Process Basically “Discovers” The inherent RT Hardness Level Of Each ProposedManufacturer’s Device
RT Assured Means RT Threshold of A Manufacturing Process is Known and Meets Requirementwith Adequate Safety Margin
Critical: RTA Certification Is Actually On A Manufacturer’s Process, Therefore: RT Thresholds Are Very Process Dependent
RT Thresholds Are Process Consistency DependentNo Intrusive Process Controls Allowed“Controls” Driven By Market And Efficiencies - NOT RT
Each RTA Certified Process Must Be:Monitored (30 Day Cycle)Assessed Prior to Each Procurement
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WHAT IS RTA?RADIATION TOLERANCE ASSURED
WHAT IS RTA?WHAT IS RTA?RADIATION TOLERANCE ASSUREDRADIATION TOLERANCE ASSURED
RTA is Not Radiation Hardness AssuredRTA is a Methodology Based Upon Knowledge of the Inherent RT
Hardness Level Possessed by a Microelectronic Device’s ProcessRTA is a Methodology Used To Achieve Nuclear Survivability inTactical Platforms, Systems and Equipments
=Evolved Over 20 Years On Many Different Army Systems=Designed for “Cradle-To-Grave” Nuclear Survivability
Enables Effective “Cradle-to-Grave” DMSMS And RT DMSMSManagement
Originally, used for Design, Production and MaintenanceNow, used for DMSMS and Sustainment in addition to above
Key: Partnerships
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RTA DMSMSRTA DMSMS
RTA Devices Can Become RTA Obsolete Only, Due to ProcessAlterations
Known or Unknown Process or Design ChangeKnown or Unknown Yield or Performance EnhancementsInadequate Quality Control
Any of Above Alterations Can Drastically Reduce RT ThresholdsEffectively Making the Device Obsolete Even Though Available
Usually, Users Unaware of “MINOR” Process Alterations Some ofWhich Degrades Thresholds
Probability of a Process Alteration Occurrence Has Been IncreasingDue to Scaling, COTS Usage, and Economies
Probability of Resulting RTA Impact Has Also IncreasedDramatically
BOTTOM LINE: All Device That Become DMSMS Become RT DMSMS All Devices That Become RT DMSMS Do Not Become DMSMS
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DEFINING THE PROBLEMDEFINING THE PROBLEMDESIGNDESIGN
5-10 YRS.
UTILIZE MOSTLYMATURE TECHNOLOGIES
ALREADY 3-5 YRS OLD
LIMITED DESIGN FLEXIBILITY FOR FUTURE
INSERTIONS RTA, COTSTECHNOLOGY, AND DMSMS INSERTIONS
LIMITED COORDINATIONBETWEEN PARTICIPANTS
BOTTOM LINE: OBSOLESCENCE DESIGNED INTO SYSTEM.
RESULT: 1 - 2 OBSOLESCENCE CYCLES DURING DESIGNRESULT: 2 - 4 RT OBSOLESCENCE CYCLES
NEW FACTORS DMSMS PROCESS ALTERATIONS COTS TECHNOLOGY CHANGES
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DEFINING THE PROBLEMDEFINING THE PROBLEMPRODUCTIONPRODUCTION
BOTTOM LINE: OBSOLESCENCE BECOMES AN INTEGRAL PART OF PRODUCTION AND IS BUILT INTO SYSTEM’S CONFIGURATION
1-4 OBSOLESCENCE CYCLES DURING PRODUCTION2-9 RT OBSOLESCENCE CYCLES
RESULT:
LOW RATE PRODUCTION 5-25
LIMITEDCOORDINATIONBETWEEN ALLPARTICIPANTS
SEVERAL CAPABILITYENHANCEMENTS/ADDITIONS
NEW FACTORS DMSMS PROCESS ALTERATIONS COTS TECHNOLOGY CHANGES
SEVERAL UPGRADESDURING PRODUCTION LIMITED FLEXIBILITY
FOR FUTURE COTS,TECHNOLOGY, RTA AND
DMSMS INSERTIONS
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DEFINING THE PROBLEMDEFINING THE PROBLEMDEPLOYMENTDEPLOYMENT
BOTTOM LINE: MAJOR OBSOLESCENCE AND RT OBSOLESCENCE PROBLEMS THROUGHOUT DEPLOYMENT
6-13 OBSOLESCENCE CYCLES DURING DEPLOYMENT14-33 RT OBSOLESCENCE CYCLES
RESULT:
LIMITEDCOORDINATIONBETWEEN ALLPARTICIPANTS
NEW FACTORS DMSMS PROCESS ALTERNATIONS COTS TECHNOLOGY RATES
BUILT-IN LIMITED FLEXIBILITY FOR FUTURE TECHNOLOGY, COTS , RTA,
AND DMSMS INSERTIONS
LONGER DEPLOYMENTS;WAS 20 YEARS
NOW 40-83 YEARS
UPGRADE/MODERNIZATION
CYCLES, WAS 1NOW 6-10
MULTITUDE OFCAPABILITY
ENHANCEMENTS/ADDITIONS
MODERNIZATION-THROUGH-SPARES
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SOLUTIONSOLUTION
SYSTEM PRODUCTION/DEPLOYMENTSYSTEM PRODUCTION/DEPLOYMENTPARTNERSHIPS WITH OTHER GOVERNMENT PROCURING ACTIVITIES PLUS ABOVE MEMBERS AREMAINTAINED THROUGHOUT THE SYSTEM’S LIFE CYCLE, WHICH ASSURES RTA PRODUCT AVAILABILITY ANDPROVIDES FOR MANAGEMENT OF COSTS AND DMSMS, WHILE ASSURING NUCLEAR SURVIVABILITY.
SYSTEM DESIGNSYSTEM DESIGNPARTNERSHIPS ARE ESTABLISHED FOR THE PURPOSE OF DEVELOPING A PRODUCIBLE, SUSTAINABLE,UPGRADEABLE AND SUPPORTABLE NUCLEAR SURVIVABLE SYSTEM.
OTHER GOVERNMENTPROCURING ACTIVITIES
CONTRACTORS/SUB-CONTRACTORS
DEVICE MANUFACTURERS/ASSEMBLY FACILITIES AND DISTRIBUTORS
RTASSC
GOVERNMENT
CONTRACTORS/SUB-CONTRACTORS
DEVICE MANUFACTURERS/ASSEMBLY FACILITIES AND DISTRIBUTORS
RTASSC
GOVERNMENT
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WHAT IS RTASSC?WHAT IS RTASSC?WHAT IS RTASSC?
Genesis of the Radiation Tolerance Assured Source and Supply Center (RTASSC) is1980 with the Initiation of the Life-Cycle Nuclear Survivability Program at WhiteSands Missile Range. Now, RTASSC Is a Full Service Center Dedicated toprovisioning of Certified RTA Standard and Custom Semiconductors and HigherLevels of Assembly Used in Military and Space Systems.
The RTASSC Utilizes primarily the RTA Methodology to Achieve Nuclear andSpace Survivability
The RTASSC Develops Partnerships With Program Offices, Contractors and Sub-contractors, Device Manufacturers, Distributors, Third Party Manufacturers andTesting Facilities, and Other Government Agencies for the Sole Purpose ofdesigning, producing, maintaining and sustaining Nuclear and Space SurvivableSystems.
RTASSC supports the entire life-cycle of Nuclear and Space Survivable SystemsRTASSC IS A DMSMS SOLVER! AND RT DMSMS SOLVER!
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Ben
efit
s
Assures ProductAvailability
Manages DMSMSand RTA DMSMS
Reduces System Costs
Increases Confidence inSurvivability, Reliability& PerformanceFenced Long TermStorage
Promotes theMTS Concept
Manages Insertionsand Changes
PARTNERSHIPSPARTNERSHIPS
WSDsAdded
RT/RHCertified
PartsRTASSC
PROGRAM OFFICESGOVERNMENT AGENCIES
PROGRAM OFFICESGOVERNMENT AGENCIES
CONTRACTORSCONTRACTORSSUB-CONTRACTORSSUB-CONTRACTORS
SUPPLIERSSUPPLIERS
DEFENSE SEMICONDUCTORASSOCIATION (DSA)
DEFENSE SEMICONDUCTORASSOCIATION (DSA)
DEVICE MANUFACTURERSDEVICE MANUFACTURERSDISTRIBUTORSDISTRIBUTORS
ASSEMBLY FACILITIESASSEMBLY FACILITIES
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AS42C
4064-12/883CA
S42C4064-12/883C
AS42C
4064-12/883CA
S42C4064-12/883C
AS42C
4064-12/883CA
S42C4064-12/883C
AS42C
4064-12/883CA
S42C4064-12/883C
RTACCS/SEi PartnershipRTACCS/SEi PartnershipVideo Random Access Memory (VRAM)Video Random Access Memory (VRAM)
256K X 3274 LEAD PIN GRID ARRAY
Cost = $3000.00
This Module Replaces theConfiguration Shown BelowAnd:n Is a Form-Fit-FunctionDirect Replacement,Designed By SpaceElectronics Inc..
n Is Radiation Tolerant Certified to 3K rads Total Dose and5x1012 n/cm2 by the RTASSC on a White Sands Drawing.n W99M55166 (PIN # W99M5516601EPX).n Has 4 times the memory at twice the access speed.
n Is 1/3 the cost of the presentconfigurationn Is Truly a DMSMS and an RTDMSMS success story.
Circuit Card Assembly(CCA)
for ABRAMS M1A2Tank
8 X 64K X 424 LEAD DUAL IN-LINE PACKAGES
Cost = 8 x $800 =$6400.00
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Goal: Prevent DMSMS Problems Manage Life-Cycle DMSMS Provide Life-Cycle Solutions
RTA’S DMSMS AND RT DMSMSAPPROACH
RTA’S DMSMS AND RT DMSMSRTA’S DMSMS AND RT DMSMSAPPROACHAPPROACH
Overall, Proactive Approach That Can Be As Reactive AsNecessary
Proactive Centerpiece Is Integrated Roadmaps Derived From:Technology Migration And Growth Roadmaps Per
ManufacturerSystem’s Technology And Growth RoadmapsDMSMS Trends Per Manufacturer And OverallRTA And RTASSC DatabasesCommercial DatabasesWSD And Monitoring Database
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DMSMS AND RT DMSMSDMSMS AND RT DMSMS SOLUTION TOOLS SOLUTION TOOLS
In the event of DMSMS or RT non-conformance/discontinuation,RTASSC will recommend one or more of the following solutions:
a. Available Parts A form-fit-function (f3) insertion of a newer technology:
Same manufacturer Alternate manufacturer
f3 Replacement from an alternate manufacturer. A non form-fit-function (nf3) insertion of a newer technology:
Same manufacturer Alternate manufacturer nf3 Replacement from an alternate manufacturer GEMb. Wafer or Die (storage)c. Minor Circuit Re-designd. Design Consolidation/Upgrade
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e. Third Party ManufacturingThe RTASSC has Partnerships with Third Party QML Manufacturing Companies.
Die Mounting.Environmental Testing (MIL-STD-883, Methods A, B, C, and D).New design OptionNew Technology OptionCustom Testing (temperature, vibration, etc.)GEMRTA CertificationElectrical Specification CertificationEmulationReverse Engineering and Manufacturing (consolidation/upgrade)
DMSMS AND RT DMSMSDMSMS AND RT DMSMSSOLUTIONS TOOLSSOLUTIONS TOOLS
Continued -
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RTA-CTQ Process FlowRTA-CTQ Process Flow
Co-located SemiconductorTest Laboratory
CUSTOMER APPROVALDEVICE
POST-TEST(DATA
EVALUATION)
PRE-TEST(EVALUATION)
REVISIONS
LTR DESCRIPTION DATE (YR-MO-DA) APPROVED
INITIAL RELEASE 98-03-18
CONVERSION OF WSD (SHORT FORM) TO WSD (FULL FORM) 98-12-03
HITE SANDS DRAWINGCONTRACT NUMBER
1-VC-080-1A2-036SS OTHERWISE SPECIFIEDNSIONS ARE IN INCHESRANCES ONCES 3 PLACES ±
CONTRACTOR
CMDR, USAWSMRSTEWS-DT-AWSMR,NM 88002
Microcircuit, Linear, High Common-ModeRejection Differential Line Receiver,Monolithic Silicon
PREPARED BY DATE (YR-MO-DA)Lawrence S.N. Wang 98-12-03
CHECKED BYRoger Sloan
ENGINEERM. Klein
DRAWING APPROVALJohn H. O’kuma
SIZE
ACAGE CODE
09WF0 W98M2141DESIGN APPROVAL
Jim NicklausSHEET 1 OF 12
WSDPOST
IRRADIATIONTABLE
Co-located SemiconductorTest Laboratory
Gamma Total Dose (Co60)50 - 300 Rads/(Si)sec
Gamma Total Dose(Co60)
.01 - 300 Rads/(Si)sec
Neutron (Fast Burst Reactor)Fluence 10E14n/cm2
SIMULATION
Linear Accelerator (LINAC)Dose Rate 1E6-1E12Rads/Si sec
ASSESSMENT(DESIGN MARGIN)
CHARACTERIZATION TEST QUALIFICATION
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WSD DOCUMENTATIONWSD DOCUMENTATION
A White Sands Drawing (WSD) is prepared for each RT HCI, CCA orSRU
WSDs Follows SMD Format Plus:
RTASSC listed as Source of Supply
RT Table
WSD Package Includes
WSD
Certificate of Conformance to Manufacturers Specifications
Certificate of Conformance for RTA
All RTA Certified Products are Supplied to White Sands Drawings(WSDs)
WSDs are Stock Listed By DLA (To Establish Usage Data)
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DOCUMENTATIONDOCUMENTATIONWSDs FOR HCIsWSDs FOR HCIs
=Radiation Tolerance Assured performancebased documents.
=Describe Commercial, Industrial, andMilitary Grade Electronic Devices.
=Accepted by the Government and theElectronics Industry.
=The RTASSC Certifies all products listedin the WSDs to the RTA levels specifiedwithin.
=All Sources of Supply are audited andapproved by the RTASSC.
=Provides Process Monitoring
=Manufacturer’s performancespecifications are included
=RTASSC is Approved Source of Supply
REVISIONS
LTR DESCRIPTION DATE (YR-MO-DA) APPROVED
INITIAL RELEASE 98-03-18CONVERSION OF WSD (SHORT FORM) TO WSD (FULL FORM) 98-12-03
HITE SANDS DRAWINGCONTRACT NUMBER
1-VC-080-1A2-036SS OTHERWISE SPECIFIEDNSIONS ARE IN INCHESRANCES ONCES 3 PLACES ±
CONTRACTOR
CMDR, USAWSMRSTEWS-DT-AWSMR,NM 88002
Microcircuit, Linear, High Common-ModeRejection Differential Line Receiver,Monolithic Silicon
PREPARED BY DATE (YR-MO-DA)Lawrence S.N. Wang 98-12-03
CHECKED BYRoger Sloan
ENGINEERM. Klein
DRAWING APPROVALJohn H. O’kuma
SIZE
ACAGE CODE
09WF0W98M2141
DESIGN APPROVAL
Jim NicklausSHEET 1 OF 12
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From Chip
To CircuitBoard
RTARTA CERTIFICATION EVOLUTION CERTIFICATION EVOLUTION
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VALIDATIONOF CONFORMANCE
(CTQ)
VALIDATIONOF CONFORMANCE
(CTQ)
CUSTOMER’SASSESSMENT
CUSTOMER’SASSESSMENT
CUSTOMERNOTIFIED
CUSTOMERNOTIFIED
RTASSC RECOMMENDATION(S)
TO CUSTOMER
RTASSC RECOMMENDATION(S)
TO CUSTOMER
WSD Procurement WSD Procurement
WSD
RTASSC ENGINEERINGASSESSMENT
RTASSC ENGINEERINGASSESSMENT
WSDPROCUREMENT
WSDPROCUREMENT
AP
PR
OV
ED
REVISE/CREATEWSD
REVISE/CREATEWSD
CUSTOMERREVIEW
CUSTOMERREVIEW
RT DMSMS?RT DMSMS?WSD PARTAVAILABLE
WSD PARTAVAILABLE
YES
YES
YES
YESNO
NO
NO
NO
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RECEIVING AND SHIPPINGRECEIVING AND SHIPPING
RTA LAB.
SHIPPINGAND
RECEIVINGOF
FIC
EO
FF
ICE
DR
Y
NIT
RO
GE
NS
TO
RA
GE
REMSTAR STORAGE
PACKAGINGAND
PRESERVATION
SU
PP
LIE
S
Bld
g. 9
0121
Sout
h E
nd
Computerized state of theart paperless system
Requires only 4 people tooperate entire facility
All purchase requestedmade through Master Database
program
Computerized state of theComputerized state of theart paperless systemart paperless system
Requires only 4 people toRequires only 4 people tooperate entire facilityoperate entire facility
All purchase requestedAll purchase requestedmade through Master Databasemade through Master Database
programprogram
Guaranteed on-timeDeliveries within 72 hrs.
Direct access to participatingDistributors
RTASSC US
Storage Areais
Environmentally & ESDControlled
WSD PROCUREMENT
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16”x20”RTASSC RTRTASSC RT Database Database Monitoring and Tracking SystemMonitoring and Tracking System
16”x20”
APPROVEDHCI PART
APPROVEDHCI PART
NON- RECOMMENDEDPARTS
NON- RECOMMENDEDPARTS
CUSTOMEREVALUATION
(PERFORMANCE)
RTASSC DATABASE AND TRACKING SYSTEM YES
ENTER RTPARTS INTODATABASE
CUSTOMERSENDS NEW
DESIGN PARTS LIST
RTTESTING?
FORWARDED WITH
RECOMMENDATIONS
FORWARDED WITH
RECOMMENDATIONS
ENGINEERING EVALUATION
ENGINEERING EVALUATION
HCI PARTS LISTGENERATED
HCI PARTS LISTGENERATED
YES
NO
DMSMS?
DATACOLLECTION
CHARACTERIZATIONBEGINS
CHARACTERIZATIONBEGINS
ROUTINETRACKINGPROCESS
(EVERY 30 DAYS)
PROCESS CHECK@
TIME OF BUY
RTACCS TRACKING PROCESS = CHANGE NOTIFICATION = RT DMSMS IDENTIFICATION =AND SOLUTION PROCESS
DMSMS?DMSMS?
YESWSDNOENGINEERING
ASSESSMENT
ENGINEERINGASSESSMENT
NO
NO
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RTASSC Tracking SystemRTASSC Tracking SystemRTASSC Tracking System
Accesses All AlertsFor the Listed Part
PIRs Can Be Submitted byThe Customer, Vendor or
ContractorProvides a Direct Link to theArmy Materiel Command’s
Information System
Provides a Direct Link to theDefense Supply Center Columbus’s
Home Page
View White SandsDrawings in
Progress
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SUMMARYSUMMARY> Partnerships> “Cradle-to-Grave”> DMSMS and RT DMSMS Program Management Support> Third Party Manufacturing and Environmental Testing.> Initial Nuclear Radiation and Space Level Certifications> Cradle-To-Grave Nuclear Survivability Management > White Sands Drawings and Process Monitoring> HCI, Component and Circuit Card RTA Certifications.> DSCC Approved (9 February 2000) Receiving, Storage (Dry Nitrogen and Controlled
Environment), and Shipping.> Procurements> Co-located
u Semiconductor Test Laboratory with 8 Automated Testersu RTA Test laboratoryu Nuclear and Space Test Facilitiesu Circuit Analystsu Nuclear and Space Environments and Effects Expertsu Nuclear Survivability Expertsu Electromagnetic Environmental Facilities and Effects Expertsu Databases (RT, DMSMS and RT DMSMS)
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CONCLUSIONCONCLUSION
Although DMSMS Is A Major Problem, RT DMSMS Is A Larger Problem
However, With A “Good Program”, Both DMSMSs Can Be EffectivelyManaged
“Good Program” Must be Effective And Affordable Which Means Proactive,Progressive, And Flexible To Reflect Ever Changing Market, TechnologyAnd Program Factors
RTASSC Utilizes The RTA Approach, A Comprehensive Approach DevelopedOver 20 Years
RTASSC is A “Good Program” That Addresses All DMSMS and RT DMSMSConcerns During A System’s Entire Life-Cycle
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=Addressesu DMSMS and RT
DMSMS Problemsu Availabilityu Documentationu Procurements and
Deliveryu Designu Productionu Deploymentu Maintenanceu Sustainmentu Long Term Storage
=Providesu RT, NEW and Space
Effects Expertiseu Facilities and Analysisu Survivability Expertiseu RT Certificationu Databaseu RT Process Monitoring
and Trackingu Proactive DMSMS
Preventionu Reactive DMSMS
Solutionu Long-Term “Fenced”
Storage
CONCLUSION (continued)CONCLUSION (continued)RTASSCRTASSC
