What makes hitachi gst the industry leader in quality and reliability

What Makes Hitachi GST the
Industry Leader in Quality and
Reliability (是什么造就了日立
R li bilit (是什么造就了日立
全球资讯储存质量和可靠性的
资
业界领导地位)

Dr. Feng‐Bin (Frank) Sun (孙凤
斌博士)
斌博士
©2011 ASQ & Presentation Sun
Presented live on Dec 07th, 2011

http://reliabilitycalendar.org/The_Re
liability_Calendar/Webinars_
liability Calendar/Webinars ‐
_Chinese/Webinars_‐_Chinese.html

ASQ Reliability Division
ASQ Reliability Division
Chinese Webinar Series
Chinese Webinar Series
One of the monthly webinars
One of the monthly webinars
on topics of interest to
reliability engineers.
To view recorded webinar (available to ASQ Reliability
Division members only) visit asq.org/reliability
) /

To sign up for the free and available to anyone live
webinars visit reliabilitycalendar.org and select English
Webinars to find links to register for upcoming events

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liability_Calendar/Webinars_
liability Calendar/Webinars ‐
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What Makes Hitachi GST the Industry Leader
in Quality & Reliability?

是什么造就了日立全球资讯储存技术(HGST)
质量和可靠性的业界领导地位?

Frank Sun, Ph.D.孙凤斌博士
HDD Reliability Engineering
Hitachi Global Storage Technologies
US Headquarters, San Jose, California
Headquarters Jose
franksun99@yahoo.com

December 2011
ASQ Reliability Mandarin Webinar

Copyright © 2010, Hitachi Global Storage Technologies, All rights reserved.

Hitachi GST Market Segment Overview （HGST 产品市场概貌）

Hitachi provides digital storage that
Endurastar
delivers pioneering technology and Personal
QUALITY that customer can count on. Storage

Solid State
Drives CinemaStar
(SSD)

Enterprise Desktop Mobile
2.5/3.5-
2.5/3.5-inch 3.5-
3.5-inch 2.5-
2.5-inch

LifeStudio and
G-Technologygy
Ultrastar series Deskstar series Travelstar series

Copyright © 2009, Hitachi Global Storage Technologies, All rights reserved. 2

Hitachi GST Global Operations （ HGST 全球业务分布）

US Headquarters: San Jose, California
Worldwide locations: 7
Revenue: US$6B (2010)
Employees: Approximate 45,000 worldwide

Netherlands
US Headquarters
San Jose, California
Beijing, China Rochester, Minnesota

Fujisawa, Japan
Shenzhen, China Odawara , Japan
Taiwan
Prachinburi , Thailand
Hong Kong, China

Global Center Laguna, Philippines HSPC, Shenzhen, China
Singapore Established:1995
Sarawak, Malaysia
Focus: Head gimbal assembly
(HGA) manufacturing
HGST, Shenzhen, China
Established:1997
Focus: Disk manufacturing
HGSP, Shenzhen, China
Established: 2005
Focus: HDD manufacturing
g
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Headquarters R&D Manufacturing Customer Centers Logistics


2011 HP Quality Award (2011 HP 质量大奖）

• The 2011 HP Quality Award recognized
Hitachi
Hit hi GST for being first in quality among
f b i fi t i lit
all suppliers supporting every area of
Hewlett Packard's business
business.


2011 Supplier Excellence Award from Google & Sony
（2011 谷歌和索尼最佳供应商）
• Google Award: For the first time • Hitachi GST merited perfect
in its company history, Google
p y y, g scores for On-time Delivery, HDD
y,
presented the Supplier Excellence Quality, HDD Reliability and
Award to “recognize suppliers for Engineering for Random Access
their
th i commitment, quality, service
it t lit i seek performance in Google's
k f i G l '
and value-add to Google.” data center environment.

• Sony Award: For the fourth
quarter in a row, Hitachi GST
received the Number One
Supplier ranking from the Sony
Group for the best quality and
service.


World Class Quality - - Customer Ranking
（基于用户评审的世界级品质）

Hitachi Quality positions customers for success
#1 in Quality by majority of OEM customers!
Sustained Leadership for the last 4 years

1st

2nd
Hitachi Quality
as ranked
by Customers
3rd

4th
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
2006 2007 2008 2009 2010

Hitachi Confidential Copyright © 2009, Hitachi Global Storage Technologies, All rights reserved. 6

World Class Reliability - - Enterprise Products
（世界级可靠性 – 高端（性能）产品用户体验）

Field Performance: 15K RPM Server Drives
1.2%
Field Performance - - Enterprise Drives

%)
Annualized Failure rate (%
1.0%
1 0%
Competitive functions, features,
0.8%
performance, and environmental footprint
0.6% (1.6 M Hrs MTTF)

At d
demonstrated and consistent Best of
t t d d i t tB t f
0.4%
Breed Quality and Reliability
0.2%
Delivers unparalleled Total Cost of
p
0.0%
Ownership 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Months After Volume Production

Field Performance: 10K RPM Server Drives Field Performance: 7.2K RPM Nearline Drives
1.2% 1.2%
alized Failure rate (%)

1.0% 1.0%
r

r
0.8% 0.8% (1.2 M Hrs MTTF)

0.6% 0.6%
(2.0 M Hrs MTTF)
0.4%
0 4% 0.4%
0 4%
Annua

Annua

0.2% 0.2%

0.0% 0.0%
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Months After Volume Production Months After Volume Production


World Class Reliability - - Desktop & Mobile Products
（世界级可靠性 – 台式和移动（电脑）产品用户体验）

Field Performance: Mobile Drives
1.2%

%)
Annualized Failure rate (%
1.0%
1 0%

0.8% (500 K Hrs MTTF)

0.6%

0.4%
Field Performance - - Mobile & Desktop Drives
0.2%
Hitachi means RELIABILITY
0.0%
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Consistently setting best-of-breed goals . . . Months After Volume Production

And consistently outperforming to those Field Performance: Desktop Drives
goals 1.2%

1.0%

r
0.8%

0.6%
(800 K Hrs MTTF)

0.4%
0 4%
Annua

0.2%

0.0%
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Months After Volume Production


What’s Behind HGST’s World Class Quality & Reliability
（HGST世界级质量和可靠性的背后是什么？）

Customer-centered proactive Quality and Reliability philosophy
C d i Q li d R li bili hil h

Strong leadership in Quality and Reliability teams

Robust margin through Design for Reliability

Strict and consistent supplier qualification

Vigorous qualification test and Reliability Growth process

Holistic product health monitoring and proactive processes –
parametric Quality and Reliability
t i Q lit d R li bilit

“Ochibo” spirit – learn from “mistakes” through Problem Deep
Diving and continuous improvement


Define Leadership and Philosophy
D fi L d hi d Phil h
in Quality and Reliability
（确立确有效的质量和可靠性领导机制和理念）
（确立正确有效的质量和可靠性领导机制和理念）


Hitachi GST Executive Staff – Quality/Reliability Path
（ HGST 质量和可靠性的行政执行架构）

Quality and Reliability at Hitachi GST
On par in importance with other key elements of a
healthy and sustainable business
Led by Sr. Vice President

President &
Chief Executive
Officer
Offi

Strategy &
Chief Strategist
Corporate
of Data Storage
Development

Chief Technology Sales & Marketing
Quality Chief Financial
Officer Human Resources Branded Business General Counsel & Operations Officer
Japan Operations
Reliability


Hitachi GST Quality/Reliability Team
（ HGST 质量和可靠性的工作团队和功能）

End to End Quality Focus

Quality &
Reliability
R li bilit

Test and
Quality Supplier WW Head WW Media Desktop & Customer
Reliability Enterprise QA
Systems Quality Quality Quality Mobile QA Tech. Support
Engineering

Total Quality System

Includes Suppliers Processes & Technology

Design Validation
Product & Process on Monitor

Ensure Customer Delight


World Wide Reliability & Statistics Trainings
（全球性的可靠性和工程统计培训: 确保强有力的技术团队）

Training in Session China

Thailand Japan


HGST Reliability Philosophy（HGST可靠性理念）
Philosophy（HGST可靠性理念）

Eliminate customer reliability issues through:
• Early problem discovery aimed at
– Characterizing and improving design robustness
– Evaluating major components
– Systematically growing product reliability

Test beyond product specification to define design margins

Conduct accelerated stress testing whenever possible

Conduct full h
C d t f ll characterization of drive performance
t i ti fd i f

Incorporate HGST specification and key customer requirements
p p y q


HGST Reliability Slogan! (HGST可靠性口号)

Have PRIDE! (以可靠性为荣)

Put 将
Reliability 可靠性
靠性
融于
Into
每一天的
Daily 工作努力
Effort 之中


Understand Product Life-Cycle Reliability Pattern and
y y
Define Closed-Loop Reliability Activities
(了解产品全寿命期的可靠性特征; 定义闭环可靠性活动）


HDD Reliability Life Cycle Pattern - Theoretical Perception*
（产品全寿命期的可靠性特征 – 理论模型）

Early
Wearout
failure
Useful life period period
period
ate
Failure ra

TS = steady state T W = wear-out
starting time: starting time:
around 1 year 5 to 7 years
F

Cumulative operating time

* Reference (10) by Sun and Yang, 1997


HDD Reliability Life Cycle Pattern - - In Real World*
（产品全寿命期的可靠性特征 – 实际观察）

• HDD hazard rate function doesn’t
h d t f ti d ’t
follow the traditional bathtub
curve.
• g
It manifests itself as an increasing-
decreasing-stabilized pattern
during warranty.
• The time-to-steady-state is not
always one year.
year

* See Reference (3) by Sun and Zhang, 2007


Reliability In Product Life Cycle （产品全寿命期的可靠性活动）

Reliability Activities in the Life Cycle of a Product
- Interrelationships Among All Disciplines
in the Creation and Merchandising of a Product

Reliability
y
Research &
R h Growth Pre-Prototype
P P t t
Development Testing
DFR/RP/RA*
Develop Design
Specifications
p Qualification
Testing
Start
Deliver
Quality, Reliability, Maintainability
and Safety of Products,
Customer
C t On S h d l
O Schedule
Satisfaction! and at a Profit!
(Marketing Research Manufacture of
- Determine Prototype
Customer Needs) All Segments of the Organization
Must Align Themselves
g
to Attain These Objectives

End Product
Reliability Reliability
Monitoring & Demonstration
D t ti
Improvement Testing
MST/LORT** Field
* DFR: Design for Reliability Full Scale
Service Production
RP: Reliability Prediction (Field AFR
RA: Reliability Allocation Tracking)
g)
** MST: Manuf. Stress Testing;
LORT: Long-term Ongoing
Reliability Test

HGST Reliability Assessment Program (HGST 可靠性评审架构)
( 可靠性评审架构)

Design For Reliability Reliability
Reliability Growth/Maturity/Demo Monitoring and Maintenance

F Build D Build HVM EOL

Design; Historical FA Data

Design Verification/Maturity Tests

Reliability
Prediction
Reliability Growth and
Demonstration

Ongoing Reliability Monitoring Tests
O i R li bilit M it i T t

Field Reliability T ki
Fi ld R li bilit Tracking


Define Quality d R li bilit M t i
D fi Q lit and Reliability Matrices and d
Conduct Reliability Prediction and Allocation
（确定质量和可靠性参数; 进行可靠性预测和分配）


Measurement of HDD Quality and Reliability
(硬盘质量和可靠性度量)

Quality is a Snapshot & Reliability is a Motion Picture*

asurement
• Time zero defects (such as “P0”) are

Parametric Mea
Spec Level

manufacturing mistakes that escaped final P0 P1 P2

test. Additional defects that appear over time
Time “0”
0 T1 T2
(such as P1 and P2) are "reliability defects" or Time of Usage

reliability fallout.

function of time (CDF)
parameter is below
Probability th the

product spec as a
hat

e
}

c
• The quality level might be described by a
single fraction defective (outside of spec), in P0
} P1
P2

terms of % defective, defects per million Time “0”
0 T1
Time of Usage
T2

(DPM), defective parts per million (DPPM), etc.

failure (parame below
function (pdf) for time to
Probability density

product spec)
eter
P2 - P1- P0

• Reliability can be described by life

f

s
P1- P0

distribution and measured by the fraction P0

fallout over time (cumulative failure
Time “0”
0 T1 T2
probability: CDF), mean ti
b bilit CDF) time to failure
t f il Time of Usage

(MTTF), mean time between failures (MTBF), Quality and Reliability: An example
annual (annualized) failure rate (AFR), etc. of product parametric measurement
p p
as a function of time.
* Reference (4) by Sun, 2007

Component and Failure Mechanism Based Reliability
Prediction (基于元器件组成和产品实效机制的可靠性预测)

Air filter

Spindle motor

Disk
Criticality of Head-Disk Interface
– A Nanometer World
Voice coil magnet

Base machined casting

Boeing 747: 70.6m Long
Load & unload casting

Head stack assembly

PCBA & electronics
Flex circuit & pre amp device
p p


HGST Reliability Database Structure (可靠性数据库结构)

S/W

Field Return and/or Commercial
Repair & FA F/W Databases
Analysis D t
A l i Data (Bellcore
MIL-
MIL-STD 217F)

HGST
Reliability
Database
HGST Supplier Data
Internal • Life Test
Qualification
Q lifi ti • Rel. Monitor
Test Data Tests
Process
Induced
Failure Rate


Iteration of Reliability Prediction and Reliability Allocation
(可靠性的预测和分配迭代)

(2) Compare with (3-1) Meeting Target
System Reliability Target

(1) On Existing Design
& Material & Supplier (3-2) Not Meeting Target
Entry
Reliability Reliability
System Prediction Allocation Exit
Design
(5) On New Design &
Material & Supplier

(4) Improved Design &
Material & Supplier


Assure S t
A System Q lit & R li bilit Starting from Bottom
Quality Reliability St ti f B tt
-Component and Supplier Quality Monitoring
（由下而确保系统的质量和可靠性
（由下而上确保系统的质量和可靠性 - 元器件供应商品质监控）


“Web-based Component SPC” （基于互联网的在线统计过程控制）

Functions
Closely monitor supplier quality real time (Wkly to Daily)

Eliminate non-confirming/out-of-control part escape to HGST

Immediate & automatic trigger when “Out of Control” happens

Objectives and Benefits
Assure delivery of the Best-Quality HDDs to Customers.

Assure hi h Effi i
A high Efficiency and St bili ti
d Stabilization on HDD Q lit and Yield.
Quality d Yi ld


Supplier Statistic Process Control Overview
（供应商统计过程控制流程）

Define Critical Parameters Daily Review on Critical Parameters
(by “DEV” & “CE”) (by SQE)

Hitachi GST
CIP

Supplier SPC Activities
Feedback and
Analysis
SPC Plan / Analysis SPC Review
(Parameter Selection & Data Collection) (with Management)

SPC Preparation Feedback & Operation
Feedback and Improvement
Analysis

Supplier Online SPC Monitoring


Sample Charts from Component Web SPC
（基于互联网的在线统计过程控制图结果示范）


Grow/Mature Product Reliability
G /M t P d t R li bilit
During Development
（在研发阶段的产品可靠性增长和成熟）


Reliability Growth Through Extensive and Vigorous Testing
（通过全面和有力的试验进行产品可靠性增长）

System Integration Test Lab

System Integration &
Compatibility

Firmware
Root Cause FA
Performance
Issues Corrective Actions
Mechanical Detected &
Identified Preventive Actions
Electrical
Reliability Growth
Environmental Stress
E i t l St

Reliability Demonstration


Extensive and Vigorous Testing: System Compatibility
（全面和有力的试验：系统兼容性测试）

Mobile Desktop

Enterprise CE


Extensive and Vigorous Testing: Mechanical
（全面和有力的试验：机械可靠性测试）

Rotational Vibration (Shaker & Performance RV)

Vibration (Op & Non op)
Non-op)

Shock (Operational & Non-Op)

Acoustics (Sound Power or Pressure)

Rotational Shock (Non-op)

Th
Thermal (Th
l (Thermocouple and I f
l d Infrared)
d)


Extensive and Vigorous Testing: Electrical
（全面和有力的试验：电器可靠性测试）

Current / Power

Power Supply Variation

Power Line Noise Injection

Temperature and Voltage Sequencing

Position Error Signal Servo Stress

Serial Signal Analysis

Vibration S
Stress Test


Extensive and Vigorous Testing: Performance
（全面和有力的试验：性能可靠性测试）

All segments
• Mobile, Desktop, CE, Enterprise
• HDD & SSD
Industry standard Benchmarks
• IOMeter
• PCMark Vantage
• H2Bench
• SysMark
• Etc.
Customer Unique Benchmarks


Extensive and Vigorous Testing: Environmental Stress
（全面和有力的试验：环境应力综合可靠性测试）

Temperature

Humidity

Voltage

Workload/scripts


Reliability Growth during Development: Actual vs Theoretical*
（研发阶段可靠性增长：实际结果和理论预期之比较）

Expected and Actual RDT Failure Rate ‐ An Example
Expected RDT FR Actual Normalized RDT FR 90% Lower CL for RDT FR 90% Upper CL for RDT FR

12.00%

10.00%
9.11%
8.00%
ailure Rate

6.31%
6.00%
RDT Fa

4.00%
2.97%
2.25%
2.00% 2.39%
1.65% 0.92%
0.83%

0.00%
pRDT0 pRDT1 pRDT2 RDT

* Duane Model RDT Test Phases


Reliability Demonstration Test TTF Trend: Actual vs Expected
（可靠性验证试验的实效时间趋势：实际结果和理论预期之比较）

Example of RDT TTF Trend Tracking - Actual vs Expected CL
80% Lower CL (Beta=0.7) 80% Upper CL (Beta=0.7) Actual Cum Fail % CDF-(Beta=0.7)

1.4000%

1.2000% Theoretical/Expected Fail
% and 80% CL with Field
MTTF_SS = 2 Million Hr
and Beta=0.70
1.0000%

0.8000%
Actual RDT
Cum Fail %

Cum Fail %
0.6000%

0.4000%

0.2000%

0.0000%
0 200 400 600 800 1000 1200

-0.2000%
RDT TTF, Hours


Predicted MTTF vs HDD Temperature & Functional Duty Cycle
（表征平均寿命与产品温度和工作负荷关系的预测谱图）


Predicted AFR vs HDD Temperature & Functional Duty Cycle
（表征年实效概率与产品温度和工作负荷关系的预测谱图）


Ongoing Quality & Reliability Monitoring
O i Q lit R li bilit M it i
during Volume Production
（进入批量生产期间质量和可靠性的在线监控）


Manufacturing Stress Testing for Product Quality Monitoring
（产品质量监控的制造应力试验）

Drive's Sensor Temperature & Chamber Temperature and Voltage Profile
100
Drive Sensor
lsius)

90 Temperature

80
Temperatur (Degree Cel

70
60 Chamber
Temperature
50
re

Power Off Ramp
40
30
20 Power Off
Ramp
10
0
-10
Temperature & Voltage Cycling
-20
-30
Volatge Margin

-40
-50
e

-60
-70
-80

Time in Test


Manufacturing Stress Testing: Quality Control Charts
（制造应力试验：产品质量监控图）
Failure % Control Charts: Individual Week vs 4-Week Rolling
MST P-Control Individual Week P (MST) PA (MST)
PA +3Sigma (MST) PA +2Sigma (MST)
8% PA +1Sigma (MST)
7%
6%
Fail Rate

5%
R

4%
3%
2%
1%
0%

WK27
WK28
WK29
WK30
WK31
WK32
WK33
WK34
WK35
WK36
WK37
WK38
WK39
WK40
WK42
WK43
WK44
WK45
WK46
WK47
WK48
WK49
WK16
WK17
WK18
WK19
WK20
WK21
WK22
WK23
WK24
WK25
WK26

MST P-Control 4 WKs Rolling P (MST) PA (MST)
PA +3Sigma (MST) PA +2Sigma (MST)
PA +1Sigma (MST)
8%
7%
6%
F Rate

5%
4%
Fail

3%
2%
1%
0%
WK16
6
WK17
7
WK18
8
WK19
9
WK20
0

2
WK22
WK23
3
WK24
4
WK25
5
WK26
6
WK27
7

WK43
3
WK44
4
WK45
5
WK46
6
WK47
7
WK48
8
WK49
9
WK21

WK28
8
WK29
9
WK30
0

WK32
2
WK33
3
WK34
4
WK35
5
WK36
6
WK37
7
WK38
8
WK39
9
WK40
0
WK42
2
WK31


Long-Term Ongoing Reliability Test (LORT)
（长期在线可靠性试验）

Drive's S
D i ' Sensor Temperature & Voltage Profile (High)
T t V lt P fil (Hi h)

Time In Hours


What makes hitachi gst the industry leader in quality and reliability

What makes hitachi gst the industry leader in quality and reliability

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What makes hitachi gst the industry leader in quality and reliability