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Toshiba
Understanding Costs of Chip Understanding Costs of Chip Design and ManufactureDesign and Manufacture
Peter Hsu, Ph.D.Peter Hsu, Ph.D.Chief ArchitectChief Architect
Microprocessor DevelopmentToshiba America Electronics Components, Inc.
Created 22 February 2001 at the University of Wisconsin in Madison
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OutlineOutline
Manufacturing CostDesign CostPricingBig PictureSummary
§The costs, prices and revenue models in this presentation are forillustration purposes only, and have no relationship to Toshiba.
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Manufacturing CostManufacturing Cost
Functional Silicon Die– Die Size– Process Maturity
Package & Assembly– Substrate vs. Lead Frame
Frequency Yield– Production Volume
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Yield as Function of Die SizeYield as Function of Die Size
0%
25%
50%
75%
100%
25 50 100 200 400 800
Chip Size (mm^2)
Func
tiona
l Yie
ld
New Process
Volume Production
Mature Process
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Functional Die CostFunctional Die Cost
$0
$500
$1,000
$1,500
$2,000
50 100 150 200 250 300 350 400
Chip Size (mm^2)
New Process
Volume Production
Mature Process
§Assumption: 200mm (8 inch) wafers at $3,000 each
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Typical ParametersTypical Parameters
Defect Densities– New Process: 10 per inch2 (1.5 per cm2 )– Volume Production: 5 / in2 (0.8 / cm2 )– Mature Process: 2 / in2 (0.3 / cm2 )
Wafer Costs– Mature Process (e.g. 0.25µm): $2,000– New Process (e.g. 0.15 µm): $5,000
§Estimated from diverse industry sources. Data is not representative of anyparticular fab or company. Wafer costs fluctuate and increases over time.
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PackagesPackages
Lead Frame– Cheap– Poor:
• Electrically• Thermally
Substrate– Moderate Cost– Good Performance
Hermetically Sealed?
Lead Frame Punched from Tape
Encapsulation byPlastic Injection-Mold
Cavity-DownThermallyEnhanced
PlasticBall Grid Array
Typical Cost: $1
Typical Cost: $4
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Example #1: Graphics ChipExample #1: Graphics Chip
Test ($1.00)97%
Speed Yield
($0.49)
Assembly ($0.60)
1% Fallout ($0.15)
60mm Die ($6.36)
63% Functional
Yield ($3.72)
BGA Package ($4.00)
§Assumption: 200mm (8 inch) wafers at $3,000 each, defect density 0.8
Total: $16.31
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Example #2: After ShrinkExample #2: After Shrink
Test ($1.00)99%
Speed Yield
($0.10)
Assembly ($0.60)
1% Fallout ($0.08)
30mm Die ($3.08)
79% Functional
Yield ($0.82)
BGA Package ($4.00)
§Assumption: 200mm (8 inch) wafers at $3,000 each, defect density 0.8
Total: $9.68
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Process VariationProcess Variation
300 400 500 600 700 800
Frequency (MHz)
Yie
ld
Low VolumeASIC Device
Mass ProductionDevice
EquivalentSpeed ASIC
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Example #3: Speed SortedExample #3: Speed Sorted
Test ($1.00)
85% Speed Yield
($2.79)
Assembly ($0.60)
1% Fallout ($0.15)
60mm Die ($6.36)
63% Functional
Yield ($3.72)
BGA Package ($4.00)
§Assumption: 200mm (8 inch) wafers at $3,000 each, defect density 0.8
Total: $18.62
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Sanity Check: DRAMSanity Check: DRAM
Defect Density– Higher: much denser fine geometry– Offset by redundancy
Wafer Cost– More complex front end for capacitor– Offset by less metal layers (e.g. 1 W + 2 Al)
64Mbit in 0.25µm: $7??
– 0.55 µm2 cell, 65% cell area: 58mm2 die– $2,000 wafer, 84%yield: $527 die– 30¢ TSOP, $1 test/redundancy, 50¢ handling
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Design CostDesign Cost
Time– How Long Until Revenue
Resources– No. People, Experties, CAD Tools
Risk– Schedule Slip– Performance Irregularities– Reliability Problems
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Typical Project ScheduleTypical Project Schedule
Architecture
Logical Design (RTL)
Logical Verification
Physical Design (Synthesis, P&R)
Physical Verification (Timing)
Prototype Fabrication, Package
Silicon Debug
In-System Verification
2nd Physical Design
2nd Physical Verification
Production Fabrication
9 months
12 month
9 month
6 month
3
2
4
6 month
3
3
9 months
1st tapeout
customersamples
2nd tapeout
Years1 2.250.25 0.5 0.75 1.25 1.5 1.75 2 2.5 2.75 3
Variations: Startup: Architecture –6 Big Company: System Verif. +6
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Typical Manpower RequirementsTypical Manpower Requirements
Performance
Logical Design
Logical Verification
Physical Design
Physical Verification
Package Design
Reference Board Design
In-System Verification
2nd Physical Design
2nd Physical Verification
Documentation
5 – 25
5 – 25
5 - 50
2 - 30
1 - 3
1 - 5
1 - 5
2 – 10
Quarters
Range: Startup – Mature Company
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Design Cost SummaryDesign Cost Summary
$333K§ per Person Year– Low: 20p x 3y = $20M– High: 150p x 3.5y = $175M
Amortize– High Volume
• Demand Generation• Derivative Products
– High-Value System Product
§Compensation $150K + 50% Benefits + 50% Equipment + 20% Facilities
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Example #1: PC Graphics ChipExample #1: PC Graphics Chip
BGA Package ($4.00)
63% Functional
Yield ($3.72)
60mm Die ($6.36)
NRE $20M 1M parts ($20.00)
Assm+Test ($2.24)
15% Profit ($5.99)
10% Sales Cost
($3.63)
§Highest volume PC OEM product line shipped several million in year 2000
Price: $46
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Example #2: High-End RouterExample #2: High-End Router
BGA Package
($50)
9% Functional
Yield ($519)
400mm Die ($51)
NRE $20M 100K parts
($200)
Assm+Test ($10)
15% Profit ($137)
10% Sales Cost ($83)
§Chip revenue stream $100M. System revenue stream $1B?
Price: $1,050
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Return On Investment (ROI)Return On Investment (ROI)
#1: PC Graphics Chip$4M Profit $20M 4yr = 5%
• Do better by investing in S&P 500
#2: High-End Router$14M Profit $20M 4yr = 18%
• Can afford R&D for future
Derivatives Help$16M Profit $25M 7yr = 9%
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Big PictureBig Picture
Business Models– Deep Pocket
• Demand Generation + Forward Pricing• e.g. Nintendo, Sony Video Game Consoles• Variant: Startup Company Acquisition
– System Subsidy• System Sales + Support Cost• e.g. Sun Microsystem, Hewlett-Packard
Microprocessors• Variant: Subcontracted Design
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Model #1: Deep PocketModel #1: Deep Pocket
Architecture
Design
Proto Fab (600mm2 in 0.12µm)
HW Debug/Qual
Mass Production (400mm2 in 0.10µm)
Sales Channel
1st Shrink (300mm2 in 0.09µm)
2nd Shrink (150mm2 in 0.06µm)
Software Development
Promotion Campaign
Year2001 0602 03 04 05 07 08 09
0.18µm 0.12µm 0.09µm 0.06µm
18 mo.
3
12
6
3
12
15
12
12
12
0.10µm
demand
2010
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Forward PricingForward Pricing
Process Generation
Proto Fab (600mm2 in 0.12µm)
Mass Production (400mm2 in 0.10µm)
1st Shrink (300mm2 in 0.09µm)
2nd Shrink (150mm2 in 0.06µm)
Mature Process (0.06µm)
Units Shipped
Revenue, Price = $250
Net Gain: $1.8B
ROI: ($1.8B – $175M) $175M 9yr = 100% (– cost of $7.5B 2yr, ...)
Year2001 0602 03 04 05 07 08 09
0.18µm 0.12µm 0.09µm 0.06µm
$1,900
$550
$50
$27
$250
0.10µm
demand
2010
25M 30M 30M 15M
($7.5B) 0 $6B $3.3B
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Model #2: System SubsidyModel #2: System Subsidy
Example:16-Processor Server
Price: $7,000
Cost: $6,000
Volume: 50,000 units 2 years
NRE: Chip $20M + System $20M
Recovery: $400 per system
“Profit”: $600 per system
ROI: $60M $40M 5yr = 30%
“A Better Server”
NoteSystem Sales + Support Cost » Chip Sales Cost
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SummarySummary
Cost
Implementation
Architecture
Marketing
Sales
ManagementResearch
Manufacturing
Investment Profit
The Business of Making Chips