counterfeit prevention & detection strategies - smta
TRANSCRIPT
1 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Counterfeit Prevention & Detection
Strategies:
When To Do It, How to Do It
Cheryl Tulkoff
SMTA Empire Chapter
June 18, 2013
2 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Nathan Myhrvold
“I want you to remember that everything I am
saying may be wrong and I want you to
question everything that I’m saying.”
Counterfeit landscape changes rapidly!
3 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Abstract
o This workshop addresses the sources of counterfeit components and provides insights into how they occur.
o Counterfeit components are a rapidly growing area of concern. The Department of Commerce has identified a 141% increase in the last three years alone!
o Counterfeit Parts are no longer an emerging threat: they’re real, and they’re here to stay.
o A counterfeit is any item that is not as it is represented with the intention to deceive its’ buyer or user. The misrepresentation is often driven by the known presence of defects or other inadequacies in regards to performance. Whether it is used for a commercial, medical or military application, a counterfeit component can cause catastrophic failure at a critical time.
o Detection methodologies, such as visual inspection, mechanical robustness, X-Ray, XRF, C-SAM, electrical characterization, decapsulation, and marking evaluations will be compared and contrasted.
o Multiple examples of counterfeit parts identified using these techniques will be highlighted.
4 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o State of Counterfeiting – Background, Facts & Statistics
o Counterfeits Defined
o Legislation, Standards & Databases
o Establishing an Anti-Counterfeiting Program
o Detection and Failure Analysis Techniques
o Case Studies and Examples
o Device Countermeasures
o iNEMI Counterfeit Calculators
o Summary
Topics
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The State of Counterfeits
o Increasing concern across all electronics industries
o Department of Commerce measured 141% increase over past three years
o http://www.bis.doc.gov/defenseindustrialbaseprograms/osies/defmarketresearchrpts/final_counterfeit_electronics_report.pdf
o Recent DfR counterfeit activities o Military Communications
o Internet Routers
o Air Traffic Control
o Consumer (Repair)
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The State of Counterfeits
o Flood of counterfeits in the US Defense supply chain
o From 2009-2010, over 1800 suspect cases of counterfeit
electronic parts involving over 1 million parts!
o Data consistently points to China as the epicenter
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The State of Counterfeits
o Electronic Component Counterfeit Incidents Continue Record Pace as the US Department of Defense Set to Update Acquisition Rules
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Number of High Risk Suppliers, Including
Counterfeiters, Surges by More than 60% from
2002 to 2011
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The State of Counterfeits
Recent Military Case Studies
o US Navy SH-60B Helicopter
o Counterfeit EIFs installed in FLIR (thermal imaging) units from
Raytheon
o US Air Force C-130J and C27-J
o Counterfeit memory in L3 Displays
o US Navy P8A Poseidon
o Reworked parts in Boeing ice detection module
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Rank Commodity Type
% of Reported
Incidents
#1 Analog IC 25.2%
#2 Microprocessor IC 13.4%
#3 Memory IC 13.1%
#4 Programmable Logic IC 8.3%
#5 Transistor 7.6%
Source: IHS Parts Management 2012
Top 5 Most Counterfeited Semiconductors in
2011
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o ICM7170 is a microprocessor-compatible real-time clock, manufactured by Harris/Intersil o ICM7170IPG:
o -40C to 85C Temperature Range
o 24-Lead Plastic Dual-In-Line Package (PDIP)
o 20uA Maximum Standby Current at 32kHz
o ICM7170AIBG:
o -40C to 85C Temperature Range
o 24-Pin Small Outline Plastic Package (SOIC)
o 5uA Maximum Standby Current at 32kHz
o ICM7170IPG
o Counterfeiter bought for $.02
o Sold for $38.00 each as ICM7170AIBG’s
o Built around 45k/month which equals a potential gross profit of $2,000,000 per month!
Lucrative Economics of Counterfeiting
DMSMS & Standardization 2011, http://www.dmsms2011.com
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Counterfeit Parts Defined
o What are they?
o What is their impact?
o Where do they come
from?
o Identification
o Industry
Countermeasures
o Avoidance
o Mitigation
13 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
What are counterfeit parts?
o Any part or component that is not as represented
o Duplication of another manufacturer’s product
o Manufacturer’s product that failed test, inspection, or burn-in or was an engineering sample
o Empty package or wrong functionality
o Salvaged or reworked parts
o Trojans
o Parts being counterfeited include:
o Newest parts & components
o Obsolete parts
o Inexpensive parts as well as high value parts
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o Used product marked as higher grade new product
o These types of counterfeits may work
o Will not operate at the same level as the higher grade part
o May fail under stress that would be expected under normal conditions.
o Electronics recycling or salvage sources
o Fake, non-working product
o Disguised parts
o Defective Scrap
o Inside sources
o New product re-marked as higher grade product
o Like used product, re-marked new product will work, but not at the desired level of functionality.
Top 4 Types of Counterfeits
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Types of Confirmed Counterfeits
o Microcircuits o Microprocessors
o Other Microcircuits
o Memory
o Radio Frequency/Wireless
o Logic, Standard
o Special Purpose Logic
o Discretes o Electromechanical
o Thyristors
o Capacitors
o Other Discretes
o Circuit Protection/Fuses
o Diodes
o Resistors
o Sensors & Actuators
o Optoelectronics
o Power Transistors
o Rectifiers
o Small Signal Transistors
o Magnetics
o Crystals/Oscillators
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Generators of Counterfeit Parts
o Inside Job
o Failed parts off the production line
o May operate in benign environment
o Competitors
o Unknown competitor may package and label the same as a known company
o May function as a direct replacement (may not)
o Money Makers
o Fraudulent: empty package or wrong chip
o Will fail immediately
o Hackers
o Trojans: malicious code
o Security threat
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Primary Sources of Counterfeit Parts
o Most counterfeit parts come from parts brokers that deal in small and odd lots
o Low volume of obsolete parts bought off the internet
o Authorized parts distributors rarely have counterfeits because they receive them directly from the original component manufacturer (OCM)
o Regions with highest counterfeit activity:
o China
o Middle East
o Eastern Europe
o But truly a global problem!
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China & US dominate but true origin is hard to identify
Counterfeit Origins
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Environmental Legislation Impact
o Provides additional opportunities
o Recycling
o Need for obsolete SnPb parts
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What is the Impact of Counterfeit Parts?
o Cost
o Reputation
o Security
o Failure
o Risk and impact varies based on type of counterfeit and
operational environment
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o Visible Costs
o Revenue Loss
o Device level anti-counterfeiting measures
o Personnel measures
o Hidden Costs
o Avoiding potentially lower cost manufacturing companies
or regions of the world
o Reputation / Brand
o Loss of Credibility to buyers
Cost Impacts of Counterfeiting to
Semiconductor Manufacturers
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o Training
o Tracking
o Inspection
o Testing
o Paperwork
o Control
o Analysis
o Procedures
Anti-counterfeiting Personnel Costs
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o Procurement training
o Limiting potential sources and purchasing controls
o Staff/operator training
o Incoming product inspection
o Time, tracking, test equipment
o Control and testing of product sourced from non-approved or
infrequently used sources.
o Loss of manufacturing time and output while re-sourcing device
if counterfeits are found or delivered
o Costs if counterfeit gets into manufacturing process
o Rework or scrap
Equipment Producer Costs
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End Component User Costs
o Additional servicing and spares
o Premature equipment failure
o Equipment downtime
o Defects or bugs causing malfunction
o Legal expenses: downtime, damage, failure to perform, injury, loss
o Military & national security
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Counterfeit Databases, Standards, and
Legislation
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o Founded in 1995, ERAI is an information services organization that monitors, investigates and reports issues affecting the global hi-tech electronics supply chain.
o ERAI provides tools to mitigate risks on substandard parts, counterfeit parts, vendors and even customers.
o Subscribers include OEMs, CMs, Distributors, OCMs, government agencies and industry associations.
o Founding participant in SAE International G-19 Counterfeit
o www.erai.com
ERAI (Electronic Retailers Association
International)
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o Government - Industry Data Exchange Program
(GIDEP) is a cooperative activity between government
and industry
o Seeks to reduce/eliminate expenditures of resources by
sharing technical information.
o Maintains suspect counterfeit database
o www.gidep.org
GIDEP
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IDEA, IACC
o Independent Distributors of Electronics Association
(IDEA), www.idofea.org
o Non-profit trade association representing distributors of
electronic components
o IDEA-STD-1010-B: Acceptability of Electronic
Components Distributed in the Open Market
o International Anti Counterfeiting Coalition
o IACC is the world's largest non-profit organization
devoted solely to protecting intellectual property and
deterring counterfeiting
o www.iacc.org
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US Government Legislation
o 2012 U.S. National Defense Authorization Act (NDAA)
o Added regulations for counterfeit part detection and
avoidance.
o October 3, 2012 updates to the DFAR supplement
implemented portions of section 818 of NDAA that must add
definitions specific to counterfeit parts, define contractors'
responsibilities, and clarify the government's role.
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Recent DoD Updates
o May 16, 2013: Long-awaited proposed Defense Federal Acquisition Regulation Supplement on detection and avoidance of counterfeit parts was released for comment.
o Required by Section 818 of the 2012 National Defense Authorization Act, the DFARS was to have been in place by Sept. 27, 2012.
o Instead, a “proposed rule” with comments due on or before July 15, 2013.
o Little detail in the proposed rule.
o The statute clearly directed the U.S. Department of Defense to establish special requirements for contractor processes to avoid counterfeit parts
o Proposed rule largely avoids this
o Folds counterfeit parts prevention into obligations that govern contractor purchasing systems.
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DoD Memorandum
o “Overarching DoD Counterfeit Prevention Guidance.’”
o In the memo, the department laid out an actionable
definition of counterfeit material and also emphasized
the importance of taking immediate action to apply
existing policy and procedures, prior to establishing new
DoD policy and procedures or waiting for forthcoming
changes to the Defense Federal Acquisition Regulation
Supplement (DFARS).
o http://www.dmsms2012.com/images/Counterfeit-
Prevention-Guidance.pdf
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DoD Definition of Counterfeit o Under the proposed regulations, a counterfeit part is:
o An unauthorized copy or substitute part that has been
identified, marked, and/or altered by a source other
than the part’s legally authorized source and has been
misrepresented to be from a legally authorized source;
o An item misrepresented to be an authorized item of the
legally authorized source; or
o A new, used, outdated, or expired item from a legally
authorized source that is misrepresented by any source
to the end-user as meeting the performance
requirements for the intended use.
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o Director’s policy memo dated 21 July 2011
o Report suspect and confirmed counterfeits to the Government-Industry Data Exchange Program (GIDEP) as Agency Action Notices
o Notification of criminal investigative organization, identified users, & DLA’s Counterfeit Material Team
o “It is an unacceptable practice to report a suspect counterfeit item after a protracted period of time trying to conclusively determine an item is suspect or actually counterfeit”
Defense Logistics Agency (DLA)
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o AS5553 “Counterfeit Electronic Parts; Avoidance, Detection, Mitigation, and Disposition”
o Provides 7 basic requirements for controlling counterfeit part threat
o Control Plan, addressing
o Obsolescence management
o Purchasing Practices
o Purchasing Documentation
o Receiving Inspection
o In process investigation
o Material Control
o Reporting
SAE AS5553 – The Aerospace Standard
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o ARP 6178-2011, ‘‘Fraudulent/Counterfeit Parts; Tool for Risk Assessment of Distributors’’
o Number of Standards now under development
o SAE AS 6081 ‘‘Counterfeit Electronic Parts; Avoidance Protocol, Distributors’’
o SAE AS 6174‘‘Counterfeit Materiel; Detection, Mitigation, and Disposition’’,
o SAE AS 6171 ‘‘Test Methods Standards; Counterfeit Electronic Parts’’
o SAE ARD 6884 ‘Terms and Definition – Fraudulent/Counterfeit Electronic Parts’’.
SAE: The Aerospace Standard Series
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o SEMI® is the global industry association serving the manufacturing supply chain for the micro- and nano-electronics industries
o www.semi.org
SEMI Anti-
Counterfeiting
Standards
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EIA/G-12 JEDEC
o EIA/G-12 Recommendation
o “only procure from the Original Component Manufacturer (OCM)
that makes and warranties the part or material or their designated
franchisees.”
o Procuring from OCM’s
o Unrealistic for Military / Government programs
o Volumes too low
o Procuring from designated franchisees
o Component availability from designated franchisees is often
similar to that of OCM
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EIA/G-12 Committee Strategy
o TB-0003-2009: Counterfeit Parts & Materials Risk
Mitigation
Prevention
Detection
Mitigation
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EIA/G-12 Statistical Analysis
o A Destructive Physical Analysis (DPA) should be
conducted in accordance with MIL-STD-1580 on a
random sample with a minimum of a 90% confidence
level (i.e. 22 piece sample, C =0) at a program
approved laboratory. A sample (22 pieces) should be
selected from each lot / date code
o EIA now rolled into JEDEC
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o Suspect Counterfeit Material Product Quality Deficiency Reports (PQDRs):
o Total Reported
o Total Closed and Verified
o Total Closed Other (i.e., final investigation showed they were not counterfeit)
o Federal Stock Code Identifier
o Source of supply of counterfeit material
o Location where suspect counterfeit material was detected
o Criticality of Item (Safety of flight, SUBSAFE, etc.)
o Action taken (e.g., stock screen, purge stock, suspend)
Counterfeit Metrics: NAVSEA Example
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Counterfeit Reporting
o For counterfeit or suspect counterfeits:
o Do not return parts!
o Segregate, quarantine, recall
o Report to stakeholders and GIDEP, ERAI databases
o Report to authorities
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Establishing an Anti-Counterfeiting
Protection and Detection Program
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Obstacles to a Successful Anti-Counterfeit
Program
o Complacency
o Won’t or can’t happen here
o Hasn’t happened yet
o Unclear ownership of issue
o Not understanding or underestimating the threat
o Only expensive parts are counterfeited
o Buy from an “American” company
o Parts use latest design
o Distributor provides a Certificate of Conformance (C of C)
o Receiving inspection or test process will catch fakes
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Obstacles to a Successful Anti-Counterfeit
Program
o Federal Acquisition Regulation (FAR)/ Defense (DFAR) issues
o FAR/DFAR says use the lowest bidder
o Need to meet Small Disadvantaged Business quota
o If I restrict where I buy from, I will pay more money
o Supply chain excuses or push back
o Expensive: here’s the bill for it, $$$
o “You want to know every time I buy a high risk part?”
o Other customers don’t have the requirement
o Liability
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o Affordability is key
o No one size fits all strategy
o Mitigations must pass the cost versus outcome test
o Counterfeit Parts are no longer an emerging threat.
They’re real, and they’re here to stay.
Obstacles to a Successful Anti-Counterfeit
Program
47 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Research
o Carefully Select Sources
o Implement Purchasing Best Practices
o Perform Lot Validation Testing
Cost-Effective Counterfeit Protection
Approach
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o Do Your Homework
o Contact Original Component Manufacturer (OCM) and
franchise distributers first
o Confirm product status
o Is the product end of life (EOL)?
o Check for authorized aftermarket sources
o Determine if/when the product went EOL
o Determine EOL production lot date codes
o Try to locate a known good device
o Check with industry sources like ERAI or GIDEP for
counterfeit activities of the product needed.
Counterfeit Protection Strategies
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o Choose Sources Wisely
o Don’t use cost as sole/primary criteria for purchase
o Quality Product is goal
o Use industry sources to evaluate potential suppliers
o Ask for accreditations, certifications & memberships like ISO9011, AS9120, IDEA-1010, ERAI or IDEA Members
o Audit sources
o Purchase only from suppliers who have implemented and are committed to counterfeit avoidance practices
o Understand warranty and payment terms
o Create a list of approved, trusted suppliers and use them
Counterfeit Protection Strategies -
Continued
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o Clearly communicate objectives and needs
o Create company policy on counterfeits
o Look for product in stock, not just availability
o Ask if the product is traceable back to the OCM
o Don’t buy COD
o Negotiate terms or use escrow services.
o Allows time for authenticity checks & testing to be
performed before paying
Purchasing Best Anti-Counterfeiting Protection
Practices
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o Before buying, ask for photos and evidence
o Images of component front and back
o Compare date codes and EOL date for product
o Compare marking with known-good product
o Do research now as it will save money later
o Understand the product warranty
o Anything less than 30 days is a RED flag
o If supplier does not have confidence in the product,
why would you?
Purchasing Best Anti-Counterfeiting Protection
Practices
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Complex Supply Chains
μcircuit
design
Fab
Avionics
OEM
Ass’y
Dist.Test
•Multiple points of entry
• Porous return policies
Lloyd Condra, Boeing
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o Broker or Independent Distributor Basics
o Not all Brokers & Independent Distributors are the same
o Many have minimal Quality Systems and no ESD, storage, or
handling controls.
o Some have no experience with semiconductors
o The Internet has created virtual companies
o Traceability back to the original OCM is unavailable
o Limited or no product warranty or support
o Buying obsolete products requires more diligence, not less
Broker 101
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o Define Test Plan based on your level of risk
o What is your application? Commercial? Military?
o Define your test plan to meet risk mitigation needs
o Put requirements in writing and be as detailed as
possible
o Require documented reports of all validation tests
o Copy of lot information detailing all tests performed and
results
o Die ID Photos, X-Ray Photos, etc.
Evaluate & Validate ALL broker material
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o Chose a reputable Test Lab/Partner based on
accreditations and capabilities, not on price alone.
o Ask for details of test plan prior to starting test
o If your supplier provides Lot Validation Testing in the
purchase price:
o Provide your test requirements to your supplier
o Compare their test plan against your risk mitigation
needs
o Understand what you are paying for
o Ask who will be performing the testing on your material
Evaluate & Validate ALL broker material
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Designated Franchisees
o Military / Government contractors standardizing sourcing plans
o Lists of approved sources (Authorized Source Directory)
o Other sources by exception and with specific approvals
o Approval process
o Audit based on quality system
o Risk assessment to the program
o Development of an inspection / test plan
http://www.authorizedcomponents.com/manufacturers.html
Use of Authorized Franchisees does not eliminate risk
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o Many unsafe part & supplier sources
o Online Broker Search Engines
o Maverick procurement methods or spending limits
o Google
o These are counterfeit ports of entry
o Rapid access to millions of parts
o Minimal membership requirements
o Quick & easy access to a large audience of buyers
Counterfeit Sources
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o Direct from the Factory (Original Component
Manufacturer, OCM)
o Approved Vendor / Manufacturer (AVL / AML)
o Franchised and Authorized Sources
o Approved Independent Distributors
o ERAI Members
o Qualified Sources of Supply
o Suppliers
o Manufacturers
o Parts (or alternates meeting the above criteria)
Trusted Supply Chain
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Qualified Supplier Resources
o Use industry resources!
o DSCC QSLD
o Pre-qualified distributors
o Semiconductors and Microcircuits
o Distributors with demonstrated
quality assurance practices
o http://www.dscc.dla.mil/downlo
ads/VQGeneral/QSLD_Booklet.
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Decision Process
o If prevention is not realistic, when to detect?
o How to mitigate?
o Entry for counterfeit components is cost
o Cost to procure < cost of redesign (+ requal, etc.)
o If cost to mitigate is too high, then redesign
o How to determine the appropriate cost to detect and
mitigate?
o Driven by probability / mission risk / volume matrix
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Decision Matrix
Probability of
Counterfeit
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Threat Evaluation
o THREAT ASPECTS
o Probability
o Knowledge of Part
o Timing of Effect
o Where Part Can be
Found
o Destructiveness
o OBSERVABILITY
o Measureable
o Accessible
o No damage
o Intermittent
o Unknown Latency
o Provokable
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Counterfeit Probability
o Probability of counterfeit (per shipment) tends to display
order of magnitude dependence on component source
o May vary based on supply chain and component technology
Known: Existing business relationship
Unknown: No existing business relationship (e.g., eBay)
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Case Study
o Telecom OEM procures one reel of capacitors from known broker
o End-of-life (EOL) product
o Decision Matrix
o DfR recommended that $10K to $100K should be spent on counterfeit detection and mitigation
o Industry ROI can be 1:1 to 10:1
Probability is 2% Volume is 4000 parts
Mission Risk is $5M Eight capacitors per CCA (500 CCAs)
$10K cost of quality ($5K COGS + $1K service + $4K loss of market)
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Counterfeit Component Inspection &
Detection Techniques Explained
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Detection of Counterfeits
o Counterfeiters are increasingly sophisticated
o Use of actual parts at the start and end of a reel
o Challenges sampling techniques
o Inspection and comparison of known-good to possible counterfeits
o Markings
o Internal structure
o Performance measurement
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Detection Techniques
T. Apple 610-531-5484 5
Risk Mitigation Methods
Visual /
Marking
Inspec-
tion
Verificati
on of
Manuf.
LDC,
SNs, etc.
Mater-ial
Analy-sisSeal Test
Radio-
graphicDPA
Minimal
Electrical
Test
Full
Electri-
cal Test
(Am-
bient)
Full
Electrical
Test (Hot
/ Cold Am-
bient)
Test &
Burn-in
Test,
Burn-in
and QCI
No Die / Non-
functionalNo No No No Yes Yes Yes Yes Yes Yes Yes
Material Content P No Yes No No Yes No No No No No
Wrong Die P P No No P Yes Yes Yes Yes Yes Yes
Re-used /
Repaired /
Salvaged
P No P P P P No No No No No
Scrapped /
RejectP No No P P P P P P Yes Yes
Mechanical
DamageYes No No P P Yes P P P P P
Mis-Handling /
StorageNo No No P No P P Yes Yes Yes Yes
Manufacturer
ChangeP P P No P Yes P P P P P
Less Reliable
PartsP P P No No P No P P P P
Reliability /
Quality IssueNo No No No P P No P P Yes Yes
ESD / EOS
DamageNo No No No No P P P P Yes Yes
Counterfeit with
functional dieP P P No P P P P Yes Yes Yes
Temperature
Range
Upmarking
No P No No No P No No Yes Yes Yes
Code:
This chart was developed from one created by Mark Marshall of Integra Technologies.
No = Unlikely to Find
Shading:
Green = Low Cost / Easily Accomplished
Yellow = Moderate Cost / Some time involved
Red = High Cost / Significant time to accomplish
Dotted Pattern = Will be found at first electrical test
Co
un
terf
eit
Co
nce
rn
P = Possibly Find
Yes = Probably Find
Detection/Risk Mitigation Methods
68 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Detection Techniques (cont.)
Add material check / seal test /
radio-graphic or do basic electrical
testing
Add full ambient electrical tests
Moderate cost / repairable-
replaceable / non-mission critical
Add QCI and other
lot acceptance
testing
Add QCI and other
lot acceptance
testing
Risk Mitigation Techniques
Selection Guide C
os
t &
Sc
hed
ule
Co
st
& S
ch
ed
ule
The more spent, the more time taken, the more confidence in reliability
Add DPAAdd DPA
Add full electrical tests
over temperature
Add full electrical tests
over temperature
Add burn-inAdd burn-in
T. Apple 610-531-5484
3/27/2007Item End-Use Requirements
Low cost / repairable
/ redundant systems
High cost / non-repairable /
mission critical
Reliabilit
y (Pro
bability o
f Dete
ction)
Add post burn-in full electrical
tests over temperature
Add post burn-in full electrical
tests over temperature
C of C Only
Check Alerts
Visual InspectionVisual Inspection
69 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Commonly Requested Tests for Counterfeits
o General product review
o Paperwork Check
o External visual inspection
o Inspection for remarking/resurfacing
o X-ray
o Lead finish exam
o Internal verification
o Basic electrical testing
70 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Missile Defense Agency (MDA) Desired:
o Documentation check
o Visual Inspection
o Marking Permanency
o Surface Finish Permanency
o Aggressive Solvents Test (destructive)
o X-Ray Fluorescence
o X-Ray
o Die Verification (destructive)
MDA Example Desired Inspection & Test
Requirements
71 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Counterfeit Analysis Techniques
• Analysis always starts with Non-Destructive Evaluation (NDE) • Designed to obtain maximum information with minimal risk of
damaging or destroying physical evidence
• Emphasize the use of simplest tools first
• Generally non-destructive techniques:
• Visual Inspection
• Electrical Characterization
• Acoustic Microscopy
• X-ray Microscopy
• X-Ray Fluorescence
• Destructive evaluation techniques
• Decapsulation
• Cross-sectioning
• SEM/EDX
72 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 72
Electrical Characterization • Parametric characterization
• Comparison of performance to datasheet specifications
• Curve tracer
• Applies alternating voltage; provides plot of voltage vs. current response
• Valuable in characterizing diode, transistor, and resistance behavior
• Time domain reflectometry (TDR)
• Release and return of electrical signal along a given path
• Measurement of phase shift of return signal indicates potential location of electrical open
• Other characterization equipment
• Inductance/capacitance/resistance (LCR) meter
• High resistance meter (leakage current < nA)
• Low resistance meter (four wire; < milliohms)
• Use of additional environmental stresses
• Semiconductor-based devices
• Temperature rise or temperature/humidity could trigger elevated leakage current
• Passive components
73 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Visual Inspection Cost & Benefit
o Cost: $1K to $3K
o What to look for:
o Part marking, date codes
o Color differences in parts
o Marking imperfections, changes, blacktopping, “ghost”
images
o Lead finish, plating variability, exposed copper, excess
solder, co-planarity of leads, bent leads
o Residues & contamination
o Package variation, thickness, radii
74 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Visual Inspection
o Which is counterfeit?
o The one with markings? Or the two that seem to have none?
o Two samples are non-functional and one functions
1 2 3
75 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Visual Inspection
o Five different capacitor types in one reel!
Capacitor Group 1,
Fluorescent Light -
Dark Brown
Capacitor Group 2,
Fluorescent Light -
Pink
Capacitor Group 3,
Fluorescent Light -
Greenish Gray
Capacitor Group 5,
Fluorescent Light -
Light Brown
Capacitor Group 4,
Fluorescent Light -
Bluish Gray
76 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Date Code Marking - Differences
2.22
12.00
3.18
12.00
Smooth
Even
Textured
Uneven
Registration (mm)
Surface
Lettering
Uniform
depth
Uneven
depth
77 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Samsung Marking Information
(1) SAMSUNG logo : SAMSUNG or SEC
top marking
type mark criteria package
SAMSUNG
marking >11.2mm
U-BGA,
W-BGA,
TBGA, FBGA
etc
(2) Year & Week
(3) Part Number : Refer to Part No. decoder page
(4) Lot Number
Country of origin not a standard Samsung marking feature
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Visual Inspection
Identical part numbers different marking styles
79 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Visual Inspection
Real or Fake? The Counterfeit Chip Conundrum, Hal Rotchadl, Premier
Semiconductor Services, Tempe, AZ, USA, IPC Printed Circuit Expo, APEX &
Designer Summit Proceedings.
Observed differences on lid corners. Part A has chamfer, and part B has
dimple
80 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Visual Inspection
Real or Fake? The Counterfeit Chip Conundrum, Hal Rotchadl, Premier
Semiconductor Services, Tempe, AZ, USA, IPC Printed Circuit Expo, APEX &
Designer Summit Proceedings.
Observed side view differences. Left part has a thin lid and
right part has a thick lid
81 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Blacktopping is a counterfeiting technique where the
counterfeiter:
o Takes components, usually real, but discarded
o Sands them to remove the original component marking
o Blacktops them in order to hide the original marking
o Prints them with fake markings.
o Dissolve the blacktop with a solvent / acetone that reveals
the true identity of the components.
o But, methods used to blacktop sanded parts improve
daily so the acetone test is no longer reliable
Blacktopping
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Examples of Blacktopping
Just under top surface, date code mismatch and hynix part
L01, remarked date code, VC36 changed to GC33 L011, hynix part
83 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Blacktopping & Acetone Wipe Test
Appearance After Acetone Wipe: change in texture and finish
Evidence of Sanding: Visible after blacktopping is removed
Photos courtesy of Oxygen Electronics
84 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Cost & Benefit
o Cost: $1K to $3K
o Verification of die and wire bonding pattern
o Internal construction of component
o Die bonding delamination issues
o Die attach voiding
85 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Microscopy
Allows for internal inspection
Latest innovations
Digital detectors
Laminography (‘virtual’ cross-
sectioning)
Produces CT models for 3D
sample analysis, virtual
micro-sectioning and
internal dimensional
Nanofocus resolution
Oblique viewing
Agilent 5DX
Nordson Dage X-Ray with 3D m-CT
86 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Inspection
o Inspect for: o Extra wire bonds o Wrong configuration of bond pads o Different die sizes o Extra heat capacity (large paddle) o Different lead frames
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X-Ray Inspection
Different die sizes L01 L011
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X-Ray Inspection
Same part but a better remarking, same die sizes, Hynix mark visible
89 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Inspection
Same part
90 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Case Study: Counterfeit FETS-X-Ray
o Customer had an issue
with DC to DC
converter failures
o Simulation models did
not predict the failures
o X-ray inspection of the
failed units
Parallel FETS
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X-Rays of Loose Parts
EZ609
Z436, Z536 Z536 Z536
Z536
Differences noted in:
-Lead frame
-Wire bonding
-Molding
92 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Technique: Automation?
o ChipCheck Project, www.smartgroup.org
o Move focus from sampling and problem to resolution
93 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Technique: Automation?
o ChipCheck Project
o Creation of an inspection system for automatic detection
of counterfeit components at incoming
o Creation of counterfeit component detection software for
fast and automatic sentencing of components. A
component database storing details of known, good,
components for comparison included
94 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Electrical Characterization Cost &
Benefit
o Cost: $3K to $6K – passives, simple actives
o One temperature for evaluation
o Cost: $15K to $80K – characterization of complex IC,
fixturing, test equipment
o Potential for circuit board design, layout and fabrication costs
to enable testing
o COMMENT: You can’t afford the risk associated with
buying expensive ICs from unknown suppliers
95 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Electrical Characterization
o Limitations of physical characteristic testing
o Parts may be re-manufactured or factory rejects in what
appears to be authentic packaging
o No conclusive identification information on the die once
decapsulated
o Therefore, some electrical analysis is helpful in determining
authenticity.
o Although full datasheet testing is highly recommended for
high reliability applications, a curve trace on each lead is a
very effective way to begin an electrical examination of the
parts.
o A known good or reference component is required.
96 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Case Study – Capacitor Electrical
Characterization
Suspect capacitor - group 3
9.720E-10
9.730E-10
9.740E-10
9.750E-10
9.760E-10
9.770E-10
9.780E-10
9.790E-10
9.800E-10
9.810E-10
9.820E-10
-60 -40 -20 0 20 40 60 80 100 120
Temperature (°C)
Cap
acit
an
ce (
F)
C7 SN2854 - 0632
limit 1
limit 2
Suspect capacitor - group 3
0.0E+00
2.0E-04
4.0E-04
6.0E-04
8.0E-04
1.0E-03
1.2E-03
-60 -40 -20 0 20 40 60 80 100 120
Temperature (°C)
Dis
sip
ati
on
fa
cto
r
C7 SN2854 - 0632
Suspect capacitor - group 2
1.049E-09
1.050E-09
1.051E-09
1.052E-09
1.053E-09
1.054E-09
1.055E-09
1.056E-09
1.057E-09
-60 -40 -20 0 20 40 60 80 100 120
Temperature (°C)
Cap
acit
an
ce (
F)
Cap 4 - Bag 10
limit 1
limit 2
Suspect capacitor - group 2
0.0E+00
1.0E-04
2.0E-04
3.0E-04
4.0E-04
5.0E-04
6.0E-04
7.0E-04
8.0E-04
9.0E-04
1.0E-03
-60 -40 -20 0 20 40 60 80 100 120
Temperature (°C)
Dis
sip
ati
on
fa
cto
r
Cap 4 - Bag 10
o Top
o Within spec
o Bottom
o Out of spec
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Electrical Characterization of Counterfeit
Diodes
Breakdown:
280V
250V
Breakdown:
50V
420V
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Electrical Characterization of Counterfeit
Diodes
Acceptable Waveform Counterfeit Waveform
Recovery measurements
99 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
This is not an authentic STS25NH3LL Part, does
not meet resistance specifications.
Its higher drain to source resistance will cause its
parallel FET partner to carry all the current.
FETs with large die have
similar resistances and
electrical performance,
regardless of lead frame
style
Electrical Characterization
100 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Mechanical Robustness - Cost & Benefit
o Cost: $2K to $5K
o Thermal cycling or other testing to verify component is
not counterfeit
101 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Counterfeit Mechanical Risk o Thermal Shock Test
o Visual Inspection (EIA-595 allows for 5 mil depth)
o 8 of 32 counterfeit capacitors had acceptable chip-outs
o 12 of 32 counterfeit capacitors had unacceptable chip-outs
o 8 of 32 Taiyo Yuden capacitors had acceptable chip-outs (very small)
Pictures of chip-outs of counterfeit capacitors (left) and Taiyo Yuden
capacitors (right)
102 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Destructive Physical Analysis (DPA)
o Cost: $7 to $10K passives
o Cost: $8 to $12K actives
o Step by Step analytical approach to identifying
whether a device is counterfeit using all tools
available.
103 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Decapsulation and Cross Sectioning
o Allows direct inspection of circuits and identification of
o Extra circuitry
o Extra layers
o Extra interconnects
104 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Decapsulation is a very valuable
tool for determining authenticity
of difficult parts.
o After performing non destructive
tests, the part may be opened for
die verification
o Does not guarantee all of the
parts in the lot are the same
o Typically cheaper than electrical
testing
Decapsulation
Plasma Etcher
Wet Etch Tanks
106 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Decapsulated Parts Inspection
Real or Fake? The Counterfeit Chip Conundrum, Hal Rotchadl, Premier
Semiconductor Services, Tempe, AZ, USA, IPC Printed Circuit Expo, APEX &
Designer Summit Proceedings.
Observed internal differences on lids. Part on left has flat lid, and
part on right has a cavity lid
107 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Decapsulated Parts Inspection
Real or Fake? The Counterfeit Chip Conundrum, Hal Rotchadl, Premier
Semiconductor Services, Tempe, AZ, USA, IPC Printed Circuit Expo, APEX &
Designer Summit Proceedings.
Chip capacitors are missing (bare pad site) on left part and
mounted on right part
108 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Cross-Sectioning
o Standard method for destructive subsurface evaluation
o Method:
o Sawing to approximate area of interest
o Potting in epoxy resins to aid polishing
o Polishing medium dependent upon materials: typically diamond, SiC, or alumina suspensions & embedded polishing cloths
o Coarse to fine (600 grit to 0.05 um) grinding sequence to eliminate damage from previous step
o Final etch often used for microstructural relief
o Optical/electron microscopy for inspection
Images courtesy of
Buehler
109 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Customer experienced two failures
o Left: known good part; center and right: bad parts
o Center part: no die; right part: cracked die
1 2 3
110 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Higher Risk Non-Destructive Inspection
• Important to understand that NDE equipment is not completely non-destructive
• Acoustic microscopy
• Can remove residues/contaminants when product is submerged in water
• Selection of bath fluid is key (distilled/deionized water; IPA; oil; etc.)
• Issue for moisture sensitive components
• X-ray microscopy
• Elevated exposure, especially with laminography, can induce damage in sensitive
components (EEPROM)
• SQUID (Superconducting QUantum Interference Device) microscopy
• Sensitivity allows for use of very low voltages; mostly non-destructive
• Thermal imaging
• Temperature rise can damage or mask fragile conductive filaments (joule heating, thermal runaway, evaporation of retained moisture)
111 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
H2O or other
fluids
Transducer
Receiver
Method for inspecting internal structures
through the application of high frequency
(>20 kHz) sound waves
Requires immersion in water (acoustic
signals reflected by air)
Allows for very accurate detection of
voids and delaminations
Options
Frequency
Transmission mode
Imaging
Acoustic Microscopy
112 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Acoustic Microscopy: Transducer Frequency
High frequency
Short focus
Low frequency
Long focus
1. Higher resolution
2. Shorter focal lengths
3. Less penetration
(Thinner packages)
1. Lower resolution
2. Longer focal lengths
3. Greater penetration
(Thicker packages)
General rules:
• Ultra High Frequency (200+ MHz) for flip chips and wafers.
• High Frequency (50-75 MHz) for thin plastic packages. (110MHz-UHF) for
flip chips.
• Low Frequency (15-30 MHz) for thicker plastic packages.
113 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Acoustic Microscopy: Transmission Mode
Pulse-Echo: One Transducer
• Uses ultrasound reflected from the sample
• Can determine which interface is delaminated
• Requires scanning from both sides to inspect
all interfaces
• Provides images with high degree of spatial
detail
• Peak amplitude, time of flight (TOF), and phase
inversion measurement
Through Transmission: Two Transducers
• Uses ultrasound transmitted through the
sample
• One scan reveals delamination at all
interfaces
• No way to determine which interface is
delaminated
• Less spatial resolution than pulse-echo
• Commonly used to verify pulse-echo
results
Through Transmission
Transmit
&
Receive
Transmit
Receive
Pulse-Echo
114 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Acoustic Microscopy
Missing die, missing bond wires and
different internal structure
Electrical shorting within the package
(delamination, electro-chemical
migration)
Electrical opens (delamination, wire
bond failure)
Insufficient thermal performance
detected (i.e. die attach, voids and
delamination)
115 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Fluorescence (XRF) Analysis
o XRF widely used determine:
o Elemental composition of components
o Lead content for compliance to the RoHS directive.
o A newer use for XRF:
o Compare a known good component to a suspect component by comparing the elements of the leads as well as the packaging.
o Software developed to compare the two in order to assist in authenticity verification.
116 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
X-Ray Fluorescence (XRF) Spectroscopy
X-ray emission signature from
x-ray source
Portable models available
Crystallographic analysis of
solid samples
117 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Example of SAC part labeled SnPb o Use XRF gun to scan
incoming BGAs to
verify Pb or Pb-free
balls
o Verify lead finish on
other parts
Pb-free Part failed to solder in Sn-Pb Process
118 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Scanning Electron Microscopy
Sample rastered with an electron
beam
Emitted electrons sorted by delay
and quantity
119 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Energy Dispersive X-Ray Spectroscopy (EDS)
• Used with SEM
• X-ray emission signature
from electron source
• Elemental analysis of
solid samples
• Identification based on
multiple emission lines (K,
L, M)
• Can’t detect light
elements: H, He, Li, Be
EDS scan of
elemental
copper
Monte Carlo
simulation of Si K-a
X-rays in an SiO2
matrix at 5 keV
(Vanderlinde, 2004)
120 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
EDS of Ceramic Capacitor
o Materials
Characterization
o Bismuth 7% to 23%
o Palladium 4% to 9%
o Silver 7% to 14%
o Titanium 26% to 34%
o Neodymium 29% to 46%
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Suspect Counterfeits
o Not all suspect counterfeits are counterfeits
o Company changed the size of the chip without a
product change notice (PCN)
o Original components that appear to be fake
New Old
Both components have the same part number
122 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Avoiding Counterfeits
Activity Relative Cost
Custom fabrication $$$$
Lifetime Buy $$-$$$
Modernize/Rev $$$$$$$$$
Screen Incoming $$
Screen Outgoing $-$$$
Buy from origin & verify $
123 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Testing & Reporting Recommendations
o Choose an analysis lab carefully
o No industry standards or accreditation for counterfeit
analysis
o Rapidly changing counterfeit landscape
o Wide variations noted among labs
o Identify the information desired from analysis
124 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Key Analysis Report Elements
o Image List – as needed
o Packaging images
o X-ray images
o XRF images
o EDS images
o Acoustic microscopy images
o Overall images of part
o Observation images
o Lead condition images
o Solvent testing images
o Internal images
o Corner radius images
o Incoming information
o Investigator & lab name
o Datasheet information
o Assessment Checklist
o Analysis & test descriptions & tools
o Electrical test results
o Overall Comments
o Results
o Summary
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Device Countermeasures:
Design for Counterfeit Avoidance
126 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Encryption on a chip
o Often cited as one of the answers to cybersecurity woes
o Difficult for small components to handle
o Intel announced a process that allows the random-number generator, which is the basis for encryption, to be made with the same semiconducting material and at the same feature size now used for modern processors.
o Smart Marking
o INK CONTAINING DNA OR OTHER BIOLOGIC MARKER FOR PREVENTION OF COUNTERFEITING AND PRODUCT DIVERSION PERCEPTIBLE WITH INFRARED LIGHT
o RF tagging
o Package Authentication - This method makes it extremely difficult to counterfeit the data on RFID tags
o Data acts as an electronic security marker to automatically authenticate genuine product packaging.
o Shipment tracking
Examples of Device Level Countermeasures
127 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Physically unclonable functions (PUFs) provide one way to tie a device to its mark of authenticity.
o Each IC is subtly different to its peers on wafer, even though all that make it through test will operate in the same manner.
o For example, internal srams have subtle biases such that, when they are first powered up, they contain a pattern of 1s and 0s that is essentially random from die to die, but which is consistent from power cycle to power cycle for that die. Repeatability can be as high as 80% under different test conditions.
o This pattern can be used as an unclonable device 'fingerprint' that, together with a digital certificate stored as part of the manufacturing and test process, guarantees authenticity
o With the necessary hardware in place, a secret key can be injected into the device at wafer test.
o Followed by injection of a digital certificate bound to the secret key at the assembly and binning stage.
o Provides a certificate that has been securely signed by the OCM and which supports all downstream anti counterfeiting measures.
o Certificate, which can be interrogated at any point, provides traceability for suppliers and end users, providing a way of guaranteeing a counterfeit free supply chain downstream.
Encryption on a Chip
128 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o The U.S. Army Research Laboratory‘s (ARL), Army Research Office‘s (ARO)
o Exploring DNA as a tagging and tracking method
o optical scanning technology that can identify counterfeit electronic components
o ChromoLogic developed a tag with a biomimetic barcode that can be aligned in the proper order and decoded by an optical reader, similar to how the sequence of a DNA molecule can be read.
o http://chromologic.com/technologies-2/
o Discovered that the optical scanning technology developed to decode the biomimetic tag is capable of mapping the intrinsic surface of electronic components, providing a type of fingerprint to distinguish authentic or counterfeit circuits.
Government / Research Countermeasures
129 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o ChromoLogic has developed this
surface-scanning technology into
the DTEK system, which provides
quantitative optical inspection of
integrated circuits
Government / Research Countermeasures
The DTEK system outputs
quantitative information
about the surface of
electronic components for
use in comparative analysis.
130 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Manufacturers Countermeasures
o Complex markings on the package
o Ultra-violet ink in package marking
o Symbols or identifiers etched in the die
o Difficult to alter parts
o Traceability
131 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Countermeasures (cont.)
o Latest technique involves etch depth analysis
o Use of digital light processing (DLP) to rapidly scan surfaces for highly accurate depth measurements
o Compare to either manufacturer’s spec or known good part
132 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Mitigating Effects of Counterfeits
o Full performance screen
o Test to or beyond spec
o Test to detect fraudulent parts
o I.e., empty packages or wrong functionality
o Factory-failed parts
o Competitors parts may prove to work
o Will not detect parts with latent defects or those with
additional circuitry
133 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Prevention
o Comprehensive audit of the distributor based on their
quality system
o Risk assessment to the program
o Development of an inspection / test plan
134 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o The finished product can look like the original. Once the components are complete they may undergo a simple electrical test, such as a curve trace, but the stresses from reclaiming and die harvesting can induce severe damage causing;
o Lower life expectancy
o Curve trace irregularities
o Out of specification
o Continuity failures
o Unknown reliability
Finished Product and Dangers of
Manufactured Counterfeits
135 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o iNEMI White Paper: Development of a Methodology to
Determine Risk of Counterfeit Use
o http://thor.inemi.org/webdownload/projects/Miniaturizatio
n/Counterfeit_Whitepaper.pdf
o Risk of Counterfeit Use
o Risk of Untrusted Sources
o Counterfeit Loss & Total Cost Estimation
iNEMI Counterfeit Risk Calculators
136 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Counterfeit Loss & Cost
iNEMI Counterfeit Calculators
137 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Counterfeit Loss & Cost
iNEMI Counterfeit Calculators
138 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Counterfeit Loss & Cost
iNEMI Counterfeit Calculators
139 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Risk of Counterfeit Use
iNEMI Counterfeit Calculators
140 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Risk of Untrusted
Sources
iNEMI Counterfeit Calculators
Rating IDEA GIDEP ISO 9000 SEMI T20 AS 6081
In House
Testing
using AS
6171 (after
release of
standard)
Rating = 1 - - -
Certification as a trusted
vendor (on a white list,
such as ones required
under SEMI T20.2)
Accredited Accredited
Rating = 2 Member Member CertifiedSet of infrastructure for
authentication via web-
Not
Accredited
Rating = 3No
Member- -
Serialization when
breaking down batches- -
Rating = 4 -No
Member
Not
Certified- - -
Rating = 5 - - - No Serialization Not Accredited -
Memberships and Accreditations
Rating Inspection
Environmental
conditions for
handling, shipping,
storage
Insurance / WarrantyPolicy in case of
counterfeit occurrence
Policy in case of
suspect parts but no
actual proof of
counterfeit
Rating = 1More stringent than IDEA
recommendations
Well established controls
for adequate limits on
exposure to ESD,
moisture, dust and
mechanical stress
Full coverage of
consequential cost,
including field returns
Agreement with certified
destruction of batch,
refund and full disclosure
of source and history
Refund for returned
batch upon customer's
request
Rating = 2
As in IDEA
recommendations or
equivalent
-
Refund and
reimbursement of rework
cost
Agreement with certified
destruction of counterfeit
batch and refund
Refund for returned
batch upon suspicious
observations
Rating = 3Less stringent than IDEA
recommendationsPartial controls
Only refund for returned
suspect batchesNo policy No policy
Rating = 4Documents, shipment
packaging, labels only-
Replacement of batch or
refund for returned
components only after
proven failures
Replacement of batch or
refund for returned
components only after
proven failures
Replacement of batch or
refund for returned
components only after
proven failures
Rating = 5None (e.g. because of no
regular inspection)
No controls of ESD,
moisture, dust or
mechanical stress
No warranty Refuses refund Refuses refund
Mitigation and Controls
RatingNumber of
employees
Number of
locations in
different
countries
Business Scale Supplier History Commodity Expertise
Rating = 1 > 100 >4Annual revenue > 100
MUS$
No known Counterfeit
incidents
All Sales, Procurement,
Quality staff specializes
in this commodity only
Rating = 2 30 - 100 4Annual revenue
10 -100 MUS$
Counterfeit supply
suspected
Range of Commodity
Specialists with
> 5 years experience
Rating = 3 11 - 29 3Annual revenue
1 - 10 MUS$
1 counterfeit supply
confirmed
Some Commodity
Specialists with
< 5 years experience
Rating = 4 4 - 10 2Annual revenue
0.1 - 1 MUS$
2 - 10 counterfeit
supplies confirmed
New Commodity Supplier
with commodity
specialists
Rating = 5 <4 1Annual revenue
< 0.1 MUS$
> 10 counterfeit supplies
confirmedNo Specialist Staff
Company Characteristics
141 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Conclusions
o Counterfeits are a real threat and growing
o Complex supply chain provides multiple entry points
o Risk needs to be managed through a decision matrix
o Probability / Mission Risk / Volumes
o Helps provide clear boundaries and guidelines for mitigation practices
o Costs are not prohibitive and should be chosen as a function of risk mitigation
142 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Instructor Biography Cheryl Tulkoff has over 22 years of experience in electronics manufacturing with an emphasis
on failure analysis and reliability. She has worked throughout the electronics manufacturing
life cycle beginning with semiconductor fabrication processes, into printed circuit board
fabrication and assembly, through functional and reliability testing, and culminating in the
analysis and evaluation of field returns. She has also managed no clean and RoHS-compliant
conversion programs and has developed and managed comprehensive reliability programs.
Cheryl earned her Bachelor of Mechanical Engineering degree from Georgia Tech. She is a
published author, experienced public speaker and trainer and a Senior member of both ASQ
and IEEE. She has held leadership positions in the IEEE Central Texas Chapter, IEEE WIE
(Women In Engineering), and IEEE ASTR (Accelerated Stress Testing and Reliability) sections.
She chaired the annual IEEE ASTR workshop for four years, is an ASQ Certified Reliability
Engineer, and a member of SMTA and iMAPS.
She has a strong passion for pre-college STEM (Science, Technology, Engineering, and Math)
outreach and volunteers with several organizations that specialize in encouraging pre-college
students to pursue careers in these fields.
143 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Contact Information
• Questions?
• Contact Cheryl Tulkoff, [email protected],
512-913-8624
• www.dfrsolutions.com
• Connect with me in LinkedIn as well!