# Presentation: 157353

## - Proper IC Storage-- Counterfeiting--- “No Lead” - Fuels the Fire 

***- ******Proper IC Storage******-- ******Counterfeiting******--- ******“No Lead” - Fuels the Fire****** ***

- November 14, 2007
- John O’Boyle
- QP Semiconductor
- Santa Clara, CA

## Today’s 3 Topics

*We have a lot to cover but I hope to make it interesting and educational, too.*
_**Proper IC Storage**_
- Brief Tutorial
- Common misconceptions
_**Counterfeiting – this is an ongoing            topic**_
- How we got to the present “situation” (IMHO)
- Examples of Counterfeiting – What to look for!
_**Lead (Pb) Free, a caution**_
- A questionable journey
_**Summary**_

## Proper IC Storage

## Proper IC Storage

- Clearly for long-term programs some 	      form of storage should be considered.
- Long-term storage may present problems – practical/physical space, mechanical, financial, and counterfeit products.
- With appropriate care, ICs can be stored at the die/wafer level, or as “finished goods” (packaged).
- What do we mean by long-term storage?* *
- Commercial: 2 years is very long-term.
- Military: 20 years and beyond is common.

## Die/wafer Storagea.k.a “Die Banking”

- Successful storage methodologies include special bagging, environmental controls and periodic monitoring.
- Requires care, cleanliness (particulates and gases), and benign temperatures.
- IDMs do this. But few, if any, distributors do.
- Controlled atmosphere “dry boxes” (dry nitrogen purged storage).
- Dry bagged/vacuum storage.
- Oxygen barrier bags designed specifically for long-term storage.

## Compact – container on the right holds 9 wafers with gross die count of 64,000. (Note – Data CD in photo)
Flexible form factor – can build parts in any desired package.

- Flexible form factor – can build parts in any desired package.

***Die/wafer Storage Advantages***

## Hermetic Packages

- Minimize moisture intrusion
- 20 year storage is routine
- Metal TO “can”
- Ceramic and side-brazed packages
- DIP, LCC, flat pack, and PGA
- Keep them dry and in environments low in sulfur, chlorine, and hydrocarbons to preserve solder finish on lead frame.

## Hermetic Disadvantages/Advantages

- Cannot change package type.
- Slightly more expensive to store than die bank.
- Large storage space required.
- Easy storage infrastructure.
- Long life time storage.

## Common Misconceptionsabout Plastic

- “They” come from the manufacturer in sealed packaging and thus don’t need special handling/storage.
- “They” are rated as not-moisture sensitive and thus are okay.
- “They” are safe to store in a “normal room” environment.

## Plastic Packages

- Plastic _**is**_ *hygroscopic*
- Attracts water molecules from the environment.
- Achieve equilibrium in 4 to 28 days depending on molding compound.
- Normal room considered “wet” for plastic ICs (LAX annual average RH: +70%*)
- Store in “dry bags” or in a <10%  RH environment

- * LAX weather station - indoor data over 31 years.

**Notes:**
Singapore mean average RH is 84.4% and the average daily temp is 26.7°C

## Wait a Minute!

- “4 days?”
- That’s for the moisture to reach equilibrium, it takes a longer time for damage to occur.
- “Normal room is WET?”
- Well, when the device is turned on the die heats and the moisture is driven out.
- But you don’t normally store them powered up, do you?

## But, Water doesn’t hurt Plastic!

- It’s not the plastic we’re worried about!
- Water leaches:
- Materials out of the mold compound
- Elements in the gases in the environment
- Other materials deposited on the outside of the package.
- These corrode and degrade the aluminum pads and wires.  Which ends in device failure.
- Isn’t plastic “rated” as non-moisture sensitive?
**Yes.  But** this is for IC**/**board assembly. It is a rating for re-flow solder heat induced de-lamination and popcorning.
_**Contrary to popular belief:**_** ****	****	****	****	****	**_**It is not a rating for long-term storage!**_

## IC Storage: Good and Bad News

- Good: You _can store_ wafers, die, or packages
- Wafers or hermetic parts; store in a dry environment.
- Plastic finished goods require a dry environment with periodic monitoring.
- Having spares essentially eradicates the problem of locating EOL/obsolete parts in the future.
- Bad: May be prohibited by regulation (FAR).
- FAR often limits procurement to one or two years.
- Systems manufacturers have rarely funded this long-term procurement on their “own dollar.”

## Storage Options: Summary

##  Counterfeiting

## Counterfeiting   

- Across All Industries From Auto Parts to Cosmetics and Pharmaceuticals.
- Pharmaceuticals: $32 Billion annual loss
- One pharmaceuticals company uses GPS on armored vehicles to track and protect their Pharmaceuticals during transport.
- Ford estimates a $1 Billion loss due to counterfeit replacement parts.
- Counterfeiting Poses a Real and Serious Threat to Global Public Health and Safety.

## How BIG is the Problem?

- Estimates place 2006 losses due to 	         counterfeiting at $650 Billion dollars*!
- If ranked as National GDP – that would be the 18th largest country in the world
- Just behind Australia at $666 Billion
- Out of the 227 countries listed in the 2006 CIA World Factbook!

- *Source: **Global trade in counterfeit goods is booming** January 26, 2007 _Business Report & Independent Online_

## How did we* get Here?

***How did we* get Here?***

- Commercial Off The Shelf (COTS) – Partly to blame (IMHO)
- What was the “Original Idea”? (A quick review)
- It worked pretty well, right?
- What happened as time passed?
- Demand shifted
- NLA appeared on POs
- “Opportunists” stepped in
- What’s to be done? *(Now that the “COT” is out of the bag?)*

*** *****The Military and Aerospace Community***

## In the Beginning (Remember the $5000 hammer?) 

- The basic concept was to get state-of-the-art devices at significantly lower prices.
- That worked and as manufacturers embraced COTS, semiconductor users reported:
- Significant savings versus “Mil-spec”
- Much higher performance (basically generation jumps)
- Ok, you so hear a “Yeah, BUT ...” Coming??  

## Well, How About an “Except?”

- COTS worked pretty well – *“EXCEPT”*
- When OEMs needed “tracking” or “specials”
- When it took a long time to start a program
- When the customer wanted more systems years later
- So the exceptions created a secondary demand for custom/older/hard-to-get parts and created a     new industry – the one serving the           DMS/Obsolete Parts Market

**It’s just **
**one little, teeny**
**   ****small change**

***And ***_***Two***_*** Things Happened *********

## One - Semiconductor Demand Shifted

- Source 1965-2005:

- Forecast

## As Time Went On 

- The commercial market for ICs exploded –
- In 1965 almost 80% of semiconductor demand was gov, about 20% corp, and consumer was almost immeasurable.
- By 1995 mil/gov was 10%, corp was 62% and consumer was 28% and _**COTS**_ was entering the “mainstream.”
- In 2005 mil/gov was 4%, corporate was 44% and consumer was 52%!
- And the IDMs had lost sight of the mil/gov customer.
- And the trend is continuing – by 2010 consumer is projected to reach over 60% and mil/gov will be in the noise at 1%! [Don’t forget, COTS is in _**Consumer**_!]

## Two – Parts Became “NLA”

- As program life lengthened parts became “_**N**_o _**L**_onger _**A**_vailable.”
_***Unanticipated***_ shortages became a very real part of the problem and made long-range planning a much more important activity.
_***“***__***Unanticipated”***_ because the commercial segment (The big “C” in COTS) used a technology and then, having used it, moved on (sorry, Omar Khayyam)
- While mil/gov designed for a longer time horizon and expected the parts to be there when ordered.

**NLA**

## What Can We Do???

- First, recognize that the divergence between consumer and mil/gov demand (exacerbated by the move to COTS) means that shortages are now a part of life.
- Given that, we can 
**Store the parts, which we covered previously, or if that’s not feasible then:**
**Develop a **_**future buying plan**_**.**

## Future BuyOr - Keynesian Economics at work

- This is tricky – the shortage of obsolete COTS parts on one side with high demand on the other has created very high prices for the remaining few devices.
- And the high prices have given rise to the counterfeit market.
- We have ALL essentially created an opportunity for unscrupulous vendors to enter the market by demanding the lowest price and /or unreasonable delivery times 
- Which they are happy to say they can accommodate!

## Further Complication

- Many counterfeit products are potentially functional in systems, making detection difficult.
- Many times genuine good parts are “salted” into the mix of counterfeits.
- IDM’s don’t have the ability to trace back older products and even if they did, counterfeiters can use valid part marking and lot numbers if they copy original examples.
- Government oversight doesn’t have resources to interdict, prosecute or incarcerate/fine.

## To Illustrate: Which is the real Cypress UVPROM?

***To Illustrate: Which is the real Cypress UVPROM?***

## Which is Real?

- Couple of facts:
- Both pass all electrical tests, including temp.
- The bottom has lower power consumption and is slightly faster on some AC tests – equal on others – all well within spec.

-     Top one is original Cypress part.
-     Bottom is a QP Semi, DSCC approved, part.
-     Bottom was re-marked as Cypress by third party.

## A Closer Look at Counterfeit ICsExample: Counterfeit National LM710

- Not a Shinko “Flat” glass header
- No stress relief step @ lead egress (chipouts)
- Date code H9923 – H is correct for Philippine assembly but NSC EOL’d in 1996, final shipments 1997, NOT 1999!

***A Closer Look at Counterfeit ICs******Example: Counterfeit National LM710***

## 710 Solder dewetting

## 710s Side-by-Side

- Counterfeit LM710 DIE
- Does not appear to be National Die

- Real National LM710 Die
- Note, correct product code “D”

## Example #2: CYPRESS 7CY403

- External part marking for Cypress
- marked device. Note “suspicious”
- LOGO.  But it is pretty close.

_**The Correct Logo**_
_**For the period**_

## CYPRESS Inside?   

**403?**

- IDT Die in Cypress
- marked package

- And, it’s the wrong part
- number!

## Example #3: Signetics – LED Driver?

- Correct part number and the logo looks okay.  - WHAT’S WRONG? Look again!

- In 1996 there was no Signetics, it was Phillips!

- And the die
- shows ST!
- Date 1989!

**CC1368F**
**CC****F****9622C**

## Counterfeit and OriginalAs indicated earlier – Philips!

- Note: the correct date reference

## More on the Signetics Part

- What we received

- What it should have been

- Very high density,
- without measuring
- Probably 0.65 m.

- You can see the transistors.
- Probably 3.0 m and correct
- layout and devices for the vintage.

## Lead (Pb) Free – a good idea?

## Lead (Pb) free –  CAUTION

- Watch out for unleaded parts being sold as having Pb solder coatings – will have tin whisker problems, especially in space.
- And vice versa
- Also be aware that as Pb free promulgates the market, many Pb parts will become hard to get.
- Counterfeiters will likely have offerings here, too.
- It is possible to re-plate but yields will be affected.

## Slide 39

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
|  |  |
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## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
|  |  |
|  |  |
|  |  |
|  |  |
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|  |  |
|  |  |

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
| Replacements (5 yr average life)  | 600/5 = 120,000,000/yr  |
|  |  |
|  |  |
|  |  |
|  |  |
|  |  |
|  |  |

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
| Replacements (5 yr average life)  | 600/5 = 120,000,000 / yr |
| New plus replacements  | (66.5 + 120) = 186,500,000 / yr  |
|  |  |
|  |  |
|  |  |
|  |  |
|  |  |

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
| Replacements (5 yr average life)  | 600/5 = 120,000,000 / yr |
| New plus replacements  | (66.5 + 120) = 186,500,000 / yr |
| Or monthly total car batteries  | (186.5 / 12)  = 15,500,000 / mo  |
|  |  |
|  |  |
|  |  |
|  |  |

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
| Replacements (5 yr average life)  | 600/5 = 120,000,000 / yr |
| New plus replacements  | (66.5 + 120) = 186,500,000 / yr |
| Or monthly total car batteries  | (186.5 / 12)  = 15,500,000 / mo |
| TI – Car battery “equivalents”  | 100 / mo (from illustration) |
|  |  |
|  |  |
|  |  |

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
| Replacements (5 yr average life)  | 600/5 = 120,000,000 / yr |
| New plus replacements  | (66.5 + 120) = 186,500,000 / yr |
| Or monthly total car batteries  | (186.5 / 12)  = 15,500,000 / mo |
| TI – Car battery “equivalents”  | 100 / mo (from illustration) |
| TI is about 5.7% Semi total  | 1750 / mo for entire industry  |
|  |  |
|  |  |

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
| Replacements (5 yr average life)  | 600/5 = 120,000,000 / yr |
| New plus replacements  | (66.5 + 120) = 186,500,000 / yr |
| Or monthly total car batteries  | (186.5 / 12)  = 15,500,000 / mo |
| TI – Car battery “equivalents”  | 100 / mo (from illustration) |
| TI is about 5.7% Semi total  | 1750 / mo for entire industry  |
| “Equivalents” / total batteries | 0.0113 % (1750/15,500,000) |
|  |  |

## Some Simple Battery Math

| ’05 car & light truck  | 66,500,000 / yr – worldwide  |
| --- | --- |
| “Installed Auto Base”  | About 600,000,000 – worldwide  |
| Replacements (5 yr average life)  | 600/5 = 120,000,000 / yr |
| New plus replacements  | (66.5 + 120) = 186,500,000 / yr |
| Or monthly total car batteries  | (186.5 / 12)  = 15,500,000 / mo |
| TI – Car battery “equivalents”  | 100 / mo (from illustration) |
| TI is about 5.7% Semi total  | 1750 / mo for entire industry  |
| “Equivalents” / total batteries | 0.0113 % (1750/15,500,000) |
| Boats (2+ batteries ea), planes, industrial, trucks/busses, etc.  | Lowers further to about: 
0.008%  |

- In Other words: Of all the Pb consumed annually just in batteries,
- Semiconductors represent **0.008%**

## DC to SF = 2419 air mi x 0.008%
[less than 50% of the yellow line]

**DC to SF = 2419 air mi ****x**** 0.008%**
- [less than 50% of the yellow line]

-     **That’s about** ** the first 1000**
**   ****feet of the journey!**

***Said Another Way***

## Summary

- Storage is a reasonable solution – but planning and care are required, especially for plastic.
- Wafer/die banking is best.

## Summary

- Storage is a reasonable solution – but planning and care are required, especially for plastic.
- Wafer/die banking is best.
- Counterfeiters are getting more bold across industries.

## Summary

- Storage is a reasonable solution – but planning and care are required, especially for plastic.
- Wafer/die banking is best.
- Counterfeiters are getting more bold across industries.
- The Buyer is the Key Link in the chain!
- The IDMs have approved channels – use them!

## Summary

- Storage is a reasonable solution – but planning and care are required, especially for plastic.
- Wafer/die banking is best.
- Counterfeiters are getting more bold across industries.
- The Buyer is the Key Link in the chain!
- The IDMs have approved channels – use them!
- For DMSMS watch out for false Certs on Pb-free.

## Thank you 

- QP SemiconductorMilitary, Aerospace, and High Reliability IC Manufacturer
- Currently Supporting over 3,100 DSCC Listed Products
- John O’BoyleNew Business Development Director
- QP Semiconductor, Inc.
- 2945 Oakmead Village Court
- Santa Clara, CA 95051 USA408-737-0992 x 145408-736-8708 fax