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MSP430F5324IRGCR High Failure Rate
Failure Details
Mode 1:
Successfully downloaded firmware, but LED D1 is OFF.
Failure rate: 23.75% (1900 out of 8000)
Mode 2:
Successfully downloaded firmware, LED D1 is blinking when powered by MSP-EXP430G2 (3.5V)
When assembled to HF sensor (3V, 150mA), the board resets.
Failure rate: 12.5% (1000 out of 8000)
Mode 1 Failure Analysis
Successfully downloaded firmware, but LED D1 is OFF.
a) Current Consumption
Good unit:
By applying 3VDC to the DUT, the expected minimum operation current is at least 7.5mA.
Green LED is blinking.
Bad unit:
By applying 3VDC to the DUT, the bad unit current is only 2mA.
Green LED always off.
b) ABA Swap Analysis
We performed ABA swap on MCU between good unit and bad.
Good unit became failed after swapped MCU from bad unit.
It has the same failure symptom.
Bad unit became passed after swapped MCU from good unit.
c) Replace new MCU and Retest
We replaced new MCU on 12 units bad unit.
It turns out 9 units passed and 3 units remain failed after replaced new MCU.
d) Rework failure rate: 25% (3 out of 12)
The failure symptom for these 3 units is the same (LED OFF).
We performed ABA swap analysis on these 3 failed units by swapping MCU to a known good unit.
Good unit become failed after swap MCU from bad unit.
Bad unit become passed after swap MCU from good unit.
This shows that the raw part is defective.
Conclusion
With above findings, we can conclude that the MCU is defective. It is the failure root cause.
With 23.75% failure rate, it is suggested that the raw part is unreliable for production usage.
Mode 2 Failure Analysis
Successfully downloaded firmware, LED D1 is blinking.
But when assembled with Sensor Board, it cannot defect motion.
a) Current Consumption
Good unit:
By applying 3VDC to the DUT, the expected minimum operation current is at least 7.5mA.
Green LED is blinking.
Bad unit:
By applying 3VDC to the DUT, the bad unit current is 8.8mA slightly higher than the expected operation current. Green LED is blinking twice and off, blinking twice and off, suspect MCU is being reset.
We found bad unit RF Network card required higher voltage (>3.5V) or higher current limit (>400mA) in order to function properly.
RF Network card power reset/not able to sync up when connected to HF Sensor board.
HF Sensor board is providing 3V@150mA to RF Network card.
b) ABA Swap Analysis
We performed ABA swap on MCU between good unit and bad.
Good unit became failed after swapped MCU from bad unit.
It has the same failure symptom.
Bad unit became passed after swapped MCU from good unit.
c) Replace new MCU and Retest
We replaced a new MCU on bad unit.
Unit passed after replaced a new MCU.
Conclusion
With above findings, we can conclude that the MCU is defective. It is the failure root cause.
With 12.5% failure rate, it is suggested that the raw part is unreliable for production usage.
Hi Joyce,
MSP430 keep low PPM and high reliable.
I find you encounter high fail rate issue about F5324, could you share more details about your project?
Like power supply, code, sch...
I think maybe others reason result in so high fail rate.
Thanks!
Best Regards
Johnson
Hi Johnson,
Thanks for the reply. We did not do any design change since 2020. Everything is working fine until the current batch of MCU.
Below is the MSP circuit, it communicates with CC1101 via SPI.
Application power supply: 3V.
Programming tool: MSP-EXP430G2 3.5V
Hi Joyce,
I think such a high failure rate is abnormal, you can check whether the MSP-EXP430G2 you are used now if normal or whether the download cable is too long.
However, if there is still a problem after the normal download procedure, you can contact your FAE for failure analysis.
Thanks!
Best Regards
Johnson
Dear Johnson,
I am Dong, Test engineer in CEI Vietnam.
This is a project run by my company, I have shared detail with you
1) The waveform of pin 6 of MSP430F5324IRGCR.
a) Unit good:
This is waveform signal pin 6 of ic MSP430F5324IRGCR
b) Unit failure mode 1:
The PCBA don't have signal output (pin 6), this is Mode 1: @joyce wang mention
c) Unit failure mode 2:
The PCBA have signal output (pin 6) but failuer function test. This is mode failuer @joyce wang mention in top topic
2) Swap (unit good, unit failure)
We already swap 4 MCU MSP430F5328 from GOOD and BAD.
After swap, LED on Good unit off after programing become fail. LED on Bad unit become light up and blinking become pass
3) Raw IC Screening Test Setup
Programming tools: Launchpad MSP430G2XX Evaluation Board
MPN: MSP-EXP430G2
Software: FET-Pro-430-LITE.exe
We removed the MCU from a working (known good) DUT.
Soldered all key connections directly to the QFN64 test socket.
DUT was connected to Launchpad MSP430G2XX Evaluation Board.
Video 1 (MCU Passed) and Video 2 (MCU Passed)
Video 1 and Video 2 showing raw part IC was loaded into the test socket, a laptop running programming software “Lite FET-Pro430.exe”.
At the end of the video (after programming passed), you can see the green LED on DUT blink twice (reset), after about 3-4 seconds, LED light up permanently.
This is a normal behavior of a known good DUT
Video 3 (MCU Failed Mode 1)
Video 3 showing raw part IC was loaded into the test socket, a laptop running programming software “Lite FET-Pro430.exe”.
At the end of the video (after programming passed), you can see the green LED is totally dead.
This is known as failure mode 1.
Video 4 (MCU Failed Mode 2)
Video 4 showing raw part IC was loaded into the test socket, a laptop running programming software “Lite FET-Pro430.exe”.
At the end of the video (after programming passed), you can see the green LED on DUT blink twice (reset) and light up for a few seconds and the DUT reset again.
This is known as failure mode 2.
Raw IC Failure Rate:
So far, we have tested 40 pcs raw part IC.
Following is the test result:
Pass |
26 pcs |
Fail (Mode 1) |
11 pcs |
Fail (Mode 2) |
3 pcs |
Failure rate based on 40 pcs = 35%.
Please the video link
https://drive.google.com/drive/folders/1WCHtLRuZmdFSshT4JkDO48X5q1Wl-NzA
4) All 2,900pcs failed are from one DATE CODE/LOT : 2236/LOT:2192875UT2
5) Use DMM check GND with all PINs in the IC.
the IC good and IC bad the same value.
IC good | IC FAIL | |||||
Pin | Singal Name | Impedance to GND | Pin | Singal Name | Impedance to GND | |
1 | P6.0/CB0/A0 | Over Load | 1 | P6.0/CB0/A0 | Over Load | |
2 | P6.1/CB1/A1 | Over Load | 2 | P6.1/CB1/A1 | Over Load | |
3 | P6.2/CB2/A2 | Over Load | 3 | P6.2/CB2/A2 | Over Load | |
4 | P6.3/CB3/A3 | Over Load | 4 | P6.3/CB3/A3 | Over Load | |
5 | P6.4/CB4/A4 | Over Load | 5 | P6.4/CB4/A4 | Over Load | |
6 | P6.5/CB5/A5 | Over Load | 6 | P6.5/CB5/A5 | Over Load | |
7 | P6.6/CB6/A6 | Over Load | 7 | P6.6/CB6/A6 | Over Load | |
8 | P6.7/CB7/A7 | Over Load | 8 | P6.7/CB7/A7 | Over Load | |
9 | P5.0/A8/VREF+/VeREF+ | Over Load | 9 | P5.0/A8/VREF+/VeREF+ | Over Load | |
10 | P5.1/A9/VREF−/VeREF− | Over Load | 10 | P5.1/A9/VREF−/VeREF− | Over Load | |
11 | AVCC1 | Over Load | 11 | AVCC1 | Over Load | |
12 | P5.4/XIN | Over Load | 12 | P5.4/XIN | Over Load | |
13 | P5.5/XOUT | Over Load | 13 | P5.5/XOUT | Over Load | |
14 | AVSS1 | Over Load | 14 | AVSS1 | Over Load | |
15 | DVCC1 | Over Load | 15 | DVCC1 | Over Load | |
16 | DVSS1 | Over Load | 16 | DVSS1 | Over Load | |
17 | VCORE | Over Load | 17 | VCORE | Over Load | |
18 | P1.0/TA0CLK/ACLK | Over Load | 18 | P1.0/TA0CLK/ACLK | Over Load | |
19 | P1.1/TA0.0 | Over Load | 19 | P1.1/TA0.0 | Over Load | |
20 | P1.2/TA0.1 | Over Load | 20 | P1.2/TA0.1 | Over Load | |
21 | P1.3/TA0.2 | Over Load | 21 | P1.3/TA0.2 | Over Load | |
22 | P1.4/TA0.3 | Over Load | 22 | P1.4/TA0.3 | Over Load | |
23 | P1.5/TA0.4 | Over Load | 23 | P1.5/TA0.4 | Over Load | |
24 | P1.6/TA1CLK/CBOUT | Over Load | 24 | P1.6/TA1CLK/CBOUT | Over Load | |
25 | P1.7/TA1.0 | Over Load | 25 | P1.7/TA1.0 | Over Load | |
26 | P2.0/TA1.1 | Over Load | 26 | P2.0/TA1.1 | Over Load | |
27 | P2.1/TA1.2 | Over Load | 27 | P2.1/TA1.2 | Over Load | |
28 | P2.2/TA2CLK/SMCLK | Over Load | 28 | P2.2/TA2CLK/SMCLK | Over Load | |
29 | P2.3/TA2.0 | Over Load | 29 | P2.3/TA2.0 | Over Load | |
30 | P2.4/TA2.1 | Over Load | 30 | P2.4/TA2.1 | Over Load | |
31 | P2.5/TA2.2 | Over Load | 31 | P2.5/TA2.2 | Over Load | |
32 | P2.6/RTCCLK/DMAE0 | Over Load | 32 | P2.6/RTCCLK/DMAE0 | Over Load | |
33 | P2.7/UCB0STE/UCA0CLK | Over Load | 33 | P2.7/UCB0STE/UCA0CLK | Over Load | |
34 | P3.0/UCB0SIMO/UCB0SDA | Over Load | 34 | P3.0/UCB0SIMO/UCB0SDA | Over Load | |
35 | P3.1/UCB0SOMI/UCB0SCL | Over Load | 35 | P3.1/UCB0SOMI/UCB0SCL | Over Load | |
36 | P3.2/UCB0CLK/UCA0STE | Over Load | 36 | P3.2/UCB0CLK/UCA0STE | Over Load | |
37 | P3.3/UCA0TXD/UCA0SIMO | Over Load | 37 | P3.3/UCA0TXD/UCA0SIMO | Over Load | |
38 | P3.4/UCA0RXD/UCA0SOMI | Over Load | 38 | P3.4/UCA0RXD/UCA0SOMI | Over Load | |
39 | DVSS2 | Over Load | 39 | DVSS2 | Over Load | |
40 | DVCC2 | Over Load | 40 | DVCC2 | Over Load | |
41 | P4.0/PM_UCB1STE/PM_UCA1CLK | Over Load | 41 | P4.0/PM_UCB1STE/PM_UCA1CLK | Over Load | |
42 | P4.1/PM_UCB1SIMO/PM_UCB1SDA | Over Load | 42 | P4.1/PM_UCB1SIMO/PM_UCB1SDA | Over Load | |
43 | P4.2/PM_UCB1SOMI/PM_UCB1SCL | Over Load | 43 | P4.2/PM_UCB1SOMI/PM_UCB1SCL | Over Load | |
44 | P4.3/PM_UCB1CLK/PM_UCA1STE | Over Load | 44 | P4.3/PM_UCB1CLK/PM_UCA1STE | Over Load | |
45 | P4.4/PM_UCA1TXD/PM_UCA1SIMO | Over Load | 45 | P4.4/PM_UCA1TXD/PM_UCA1SIMO | Over Load | |
46 | P4.5/PM_UCA1RXD/PM_UCA1SOMI | Over Load | 46 | P4.5/PM_UCA1RXD/PM_UCA1SOMI | Over Load | |
47 | P4.6/PM_NONE | Over Load | 47 | P4.6/PM_NONE | Over Load | |
48 | P4.7/PM_NONE | Over Load | 48 | P4.7/PM_NONE | Over Load | |
49 | VSSU | Over Load | 49 | VSSU | Over Load | |
50 | PU.0 | Over Load | 50 | PU.0 | Over Load | |
51 | NC | Over Load | 51 | NC | Over Load | |
52 | PU.1 | Over Load | 52 | PU.1 | Over Load | |
53 | LDOI | Over Load | 53 | LDOI | Over Load | |
54 | LDOO | Over Load | 54 | LDOO | Over Load | |
55 | NC | Over Load | 55 | NC | Over Load | |
56 | AVSS2 | Over Load | 56 | AVSS2 | Over Load | |
57 | P5.2/XT2IN | Over Load | 57 | P5.2/XT2IN | Over Load | |
58 | P5.3/XT2OUT | Over Load | 58 | P5.3/XT2OUT | Over Load | |
59 | TEST/SBWTCK | Over Load | 59 | TEST/SBWTCK | Over Load | |
60 | PJ.0/TDO | Over Load | 60 | PJ.0/TDO | Over Load | |
61 | PJ.1/TDI/TCLK | Over Load | 61 | PJ.1/TDI/TCLK | Over Load | |
62 | PJ.2/TMS | Over Load | 62 | PJ.2/TMS | Over Load | |
63 | PJ.3/TCK | Over Load | 63 | PJ.3/TCK | Over Load | |
64 | RST/NMI/SBWTDIO | Over Load | 64 | RST/NMI/SBWTDIO | Over Load |
Thank you so much!
Best Regards
Tuan Dong
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