PEPR: Pseudo-Exhaustive Physically-Aware Region Testing

Recent reports indicate that existing fault models and test metrics result in substantial manufacturing test escapes that cause major system-level challenges such as silent data corruption resulting from incorrect computations. Such test escapes are often detected today after system deployment (e.g., in the field) using a variety of synthetic and application workloads. In this work, a new test metric is investigated for detecting defects that escape existing test approaches. PEPR (Pseudo-Exhaustive Physically-Aware Region) testing comprehensively analyzes both the physical layout and the logic netlist to identify single- or multi- output sub-circuits. The resulting sub-circuits are exhaustively tested to detect timing-independent combinational (TIC) defects. Analyses demonstrate that PEPR-based scan tests detect TIC defects perfectly (100%) when examining fail data from over 30,000 14nm failing chips. In contrast, existing fault models and test metrics might result in up to 95 % of TIC defects being detected fortuitously. Strategies for addressing increased test pattern count resulting from the pseudo-exhaustive nature of PEPR testing are also discussed.