How do semiconductor companies plan for aging? There has never been a truly efficient solution, and according to this article, problems are getting worse. For example, electronics in cars continue to get more complex (and more safety critical). But cars are used in very different ways after being sold, and in very different climates.
When a device is used constantly in a heavy load model for aging, particular stress patterns exaggerate things. An Uber-like vehicle, whether fully automated or not, has a completely different use model than the standard family car that actually stays parked in a particular state a lot of the time, even though the electronics are always somewhat alive. There’s a completely different aging model and you can’t guard-band both cases correctly.
Aging is dealt with by heuristics, which typically add a “safety margin” to designs. But it’s not accurate, and leaves money (chip area = $ per chip) on the table.
Moreover, margin typically isn’t just one thing. It’s actually a stack.“The foundry, with the models that they give us, includes a little bit of padding to cover themselves,” said ANSYS’ Geada. “And then the library vendor adds a little bit of padding and nobody talks about what that is, but everybody adds up this stack of margin along the way. “
But of course, the semicon industry has been dealing with emerging challenges like this for its entire existence. Each new problem starts at a low stage of knowledge, beginning with Stage 0 (nobody knows the problem exists) and usually ending at about Stage 6.