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Intelligent Reliability 4.0

Periodic Reporting for period 1 - iRel40 (Intelligent Reliability 4.0)

Reporting period: 2020-05-01 to 2021-04-30

General trend for electronic components and systems, which more and more penetrate our daily life, is higher system integration driving increasing compactness and complexity and all at acceptable cost.
iRel40 aims to find solutions to cope with the ever increasing complexity of reliability topics and to find processes, methods and digitized universal procedures.
Reliability is challenged on device and system level and faces exceptional requirements in respect to innovative applications. This requires customer acceptance and must lead to their satisfaction. Reliability must be guaranteed, when using systems in new and critical environments (corrosive chemicals, extreme temperatures), whereby new materials must be used. To cope with customer satisfaction, there is a need to predict the remaining life of a system. This topic named prognostics and health monitoring (PHM) refers to the process of predicting future reliability or determining the remaining useful lifetime of a product by assessing the extent of deviation or degradation of a product from its expected normal operating conditions.
iRel40 is important for the society as the results strengthen production along the value chain and support sustainable success of investment in European microelectronics. Through close collaboration between academy, industry and knowledge institutes on this challenging topic of reliability, the project secures more than 25.000 jobs in the 25 participating production and testing sites in Europe. The project supports new applications and reliable chips pushing important electronic markets like energy efficiency, e-mobility, autonomous driving, or IoT. This unique project brings, for the first time ever, world-leading reliability experts and European manufacturing expertise together to generate a sustainable pan-European reliability community.
iRel40 has one primary objective: Improve the Reliability by reducing the failure rate (measured in ppm).
The project has 5 overall objectives:
• Define needs and requirements for future ECS applications to drive improvements and prediction of reliability along the value chain chip, package, board/system to foster Europe's competitiveness in ECS
• Implement data values chains and cross component data analytics to speed up the learning curves by 30%
• Double the predicted lifetime for specific materials and load conditions for ECS applications
• Early detection of unexpected quality relevant events along the ECS value chain by advanced and innovative control concepts
• Reduce the failure rates by 30% and enable life time prediction with connected and new test concepts along the ECS value chain
The iRel40 project started during a challenging period with a kick-off in May 2020. The iRel40 project consists of a consortium with 75 partners from 13 European countries including Turkey. Two General Assemblies with all partners have been set up. The 2nd full project General Assembly was organized as a General Assembly Week mid-May 2021. This allowed to combine efficient work package meetings as well as to avoid parallel sessions.

The two work packages WP1 and WP6 are the project envelope. They also include the pan-European network activities. The two deliverables D1.1 and D1.2 of WP1 on specs and requirements have been worked out.
WP6 includes technical work to evaluate the project and will fully start after year 1.
Detailed technical research and development work is covered in the four work packages WP2 to WP5.

In WP2, which includes R&D on “Analytics, Theory, Cognition and Prediction”, four deliverables were elaborated. Five technical highlights have been achieved:
Data infrastructures ready for data collection, methodologies for data analysis and features extraction ready, new training data augmentation techniques developed, several data driven models are developed, new physics-based models developed. In addition holistic approaches to PHM methodology started.
In WP3, which includes R&D on “Advanced and Functional Materials and Interfaces”, first good technical results have been achieved on barriers coating and mold materials. New test infrastructure for reliability testing under specified environmental conditions has been setup. The related second milestone M3.10 on test facilities was achieved.
WP4, which includes R&D on “Production and Development Excellence, is a core of iRel40 and had an intense starting phase in respect to alignment. The deliverable D4.1 on concept definition and specification scheduled for month M06 has been worked out. Critical parameters were identified during year 1, feasibility studies were carried out in different research fields, test samples assembled and characterization started, manufacturing data set generated to train an AI, alignment among partners on specifications, data structure and model concepts, and concept developments started. Development of hardware and test boards to measure and communicate with test structures and systems is in full progress.
WP5, which includes R&D on “Holistic Testing Assessment”, had an intense starting phase with setting up the different tasks, refinement of task description and use case content. Within D5.1 requirements and Specifications w.r.t new and critical reliability testing assessment along the ECS value chain have been defined. First concepts have been proposed for increasing test coverage and speed for reliability improvement, AI based outlier detection and cognitive release methods, and reliability prediction by real time tests during system use.
WP7 (Dissemination and Exploitation) especially included the set-up of internal and external servers for info and data exchange, and first disseminations activities like participation with a booth during digital EFECS 2020 etc. In addition, a first version of the iRel40 newsletter was published.
The expected impact of iRel40 will be manifold:
Determination of the 'Physics of Failure' (PoF) for all key failure modes and interactions
Lower failure rates (ppm), reduced time to market due to faster learning curves in development and ramp up, increased lifetimes, customer satisfaction and reliability as key differentiator
Development of fast and comprehensive technology/product qualification schemes
Optimized test procedures, new reliability tests for new requirements
Speed up Time to market by preventing reliability issues and unnecessary design iterations
Creation of commonly accepted PoF based design for reliability, testing, manufacturing, DfX methods based on calibrated models and validated numerical simulations and formal approaches
Minimized impact of real physical production variations along the value chain
Strategies for field data collection, prognostic health management (PHM) and autonomic development of ECS
Enable prediction (PHM), reduce total cost of ownership, feedback to development
Reduce cost by the transition from a reactive to a predictive reliability understanding in the entire ECS value chain.
Generate unique IP on reliability subjects along the entire value chain, strengthening the market for products Made in Europe

Reliability leads to longer lifetime of products, enables sustainability of electronic devices and thus products. Improved Reliability clearly supports the European "Green Deal" strategy and thus clearly demonstrates potential for socio-economic and societal implications.