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| Title: | DIGITAL SERVICES CONSUMPTION REDUCTION |
|
| Moderator: | STOSS1::KLEIN |
|
| Created: | Tue Oct 06 1992 |
| Last Modified: | Thu Feb 06 1997 |
| Last Successful Update: | Fri Jun 06 1997 |
| Number of topics: | 318 |
| Total number of notes: | 644 |
318.0. "E2062-DA, E2056-DA Corrective Action / Findings" by QETOO::STJAMES () Thu Feb 06 1997 18:21
FYI: World-wide Program in place to work corrective action:
Regards, Carol St.James (508) 474-2484,
Consumption Reduction
CR AND REPAIR COST AVOIDANCE: E2062-DA/E2056-DA JAN 20, 1997
Carol St.James
CONSUMPTION AND REPAIR COST AVOIDANCE: E2062-DA and E2056-DA
==============================================================================
PROJECT: E2062-DA and E2056-DA Consumption and Repair
Cost Avoidance.
PROJECT DESCRIPTION: Determine the Root Cause of E2062-DA and E2056-DA
failures.
- Reduce the failure rate due to Mfg
and design problems.
- Reimbusement for Repair and
failure analysis Labor and Material from IPMT
WW CONSUMPTION COST E2062-DA X 45 = $ 429,270.75
OF FAILURES TO DATE(12/96): (33 AMERICAS, 2 A/P, 10 EUROPE )
Corrective Action Team: AMERICAS: Carol StJames / Jim DAngelo /
Wayne Ivany / Mfg and Systems Eng.
Corporate Quality; Gary Kushner,
Ray Gruda, Jim Coleman, Dan Deufel/
Don Canney / Field Teams
EUROPE : John Cronin / Tom Fleming and AYR
Teams
START DATE: DECEMBER
IMPLEMENTATION DATE: DECEMBER 15, 1996
IMPLEMENTATION EXPENSES: 0
Cost Avoidance Forecast: FY97 Cost Avoidance $ 300 K
Actual CR Savings: 1) Current Baseline Failure Rate vs
Reduced Failure Rate = Savings:
Cons QTY x STND$ = Consumption Cost Avoid.
E2062-DA ?? x $ 9,539.35
E2056-DA ?? x $ 6,880.42
Cost To Repair Avoidance
E2062-DA ?? x $ 4,880.57
E2056-DA ?? x $ 1,100.21
2) SBU Reimbursement for modules in IPMT process
Return Qty for failure analysis x
labor + material + shipping recovery from SBU
Actual Cost Avoidance$: In progress
E2062-DA CORRECTIVE ACTION UPDATE:
====================================
- Worldwide returns failure analysis will be consolidated from following
sources and provided to Ayr MFG PFT, Design and Mfg Engineering.
> JGO European Repairs
> RSG US Repairs
- DOA Direct Spares Returns
> Install Return process;
- NIO Stage II Confirmation (go/No go)
- AYR Stage I Root Cause failure analysis
> Stage II Fallout;
- NIO
- AYR
- Customer Impact Statements will be communicated back to AYR since the
goal was 1% DOA and we have exceeeded this rate.
6 MONTH
PART *DOA CONS DOA DOA
QTY QTY % GOAL
-----------------------------------------------------------
E2062-DA 4 29 13.79 % 2.0 % OR LESS
E2056-DA 16 254 6.30 % 2.0 % OR LESS
- A blitz is scheduled for release regarding the Console Patch required
when the EV5.6 Pass 2 is implemented (Appendix A preliminary copy)
- The above blitz will be included as an Insert.
- Have worked with Corp quality / systems engineering in PKO to assure
issues to date are consolidated and they have in turn shared their
status and insights.
- Module and ADG Chip preheating is being performed in RSG to prevent
cracking of the ADG Chip (which was a constant fault).
Regards,
Carol
From: QETOO::STJAMES "CAROL ST.JAMES QETOO::STJAMES DTN:275-2484 TEL:508 474-2484 FAX:275-3833FAX: 508 474-3833 OR X2770 OR X2605" 23-JAN-1997 18:21:10.62
To: YAEGER,BREEN,TCM000::OOLDERS
CC: STJAMES ,STJAMES
Subj: E2062-DA and E2056-DA Root Cause Failure Analysis and Corrective Action
To date Six main problems have been identified and corrective actions
put in place based on cooperative Teamwork with JGO, AYR, Corp.
Quality & Reliability Revenue Products Engineering, RSG Repair and
the Americas Field. Improvements have been made relating to problems and
corrective action for the E2062-DA in the following Areas:
- DC to DC Converter Solderability issue for E96
- CSALT Ceramic Chip Cracking
- ADG Chip Cracking
- MMIC component failures
- Frequency Synthesizer
- Firmware V4.3 to V3.9 (machine hang bug corrected = better diag capability)
- EV56 Pass 2 compatibility to Pass 1 (FIXED New Console/firmware resolves;
Insert/Customer Letter and V43., V3.9 firmware CD shipping with all
newbuild and any spares repaired with Pass 2 chip.
- EV56 Failures
- Unix Operating system Appication compatibility issues
More communications will be delivered to the field in near future.
Project Action:
===============
- Currently the IPMT Process / and Corp Quality & Reliability Engineering is
working with us to bring back all field failures through direct
shipment for failure analysis that has been established.
- Information is being consolidated from a World Wide Perspective.
- More to come ...
Regards,
Carol
APPENDIX A
IMPORTANT NOTICE, PLEASE READ
-----------------------------
This notice accompanies either:
- an AlphaServer 8x00 system that contains a CPU module with a new
revision of the xxxxxx CPU chip, or
- an add-on CPU module for the AlphaServer 8x00 system that contains
a new revision of the xxxxx CPU chip
CPU modules E2062-DA, revision xxx or later, include the newer revision of
the CPU chip.
A problem arises if a AlphaServer 8x00 system includes a mixture of old and
new revisions of the xxxxx CPU chip.
The new revision of the xxxxx CPU chip includes a minor enhancement that is
not utilized in the AlphaServer 8x00 system. In all other respects, the old
and new revisions of the CPU chip are fully compatible. The OpenVMS
operating system software will not execute in SMP mode if it cannot
determine that the processors are compatible.
This system, or the system into which the CPU module is going to be
installed, must have an appropriate version of the console code installed.
If OpenVMS is the operating system being used, a specific patch must be
installed. The specified console firmware and OpenVMS patch together ensure
that the test for compatibility will succeed. Failure to ensure these
conditions will prevent OpenVMS from starting some or all of the secondary
processors for inclusion in the SMP environment.
Systems running the Digital UNIX operating system are not affected, although
it is recommended that the guidelines for console version are followed.
The minimum console firmware version is V4.3
The required OpenVMS patch for V6.2-1H3 is ALPnnnnn
The required OpenVMS patch for V7.0 is ALPnnnnn
The required OpenVMS patch for V7.1 is ALPnnnnn
If this notice accompanies a CPU module, an appropriate version of console
firmware has been pre-installed. The same version of console firmware should
be loaded onto all other CPU modules in the system.
If this notice accompanies a system, an appropriate version of console code
has been pre-installed on all CPU modules in the system.
<<will add something about getting copies of console if needed to upgrade an
existing system>>
MODULE INSERT
EV56 letter, 4th draft (not released yet) that will be included in Pass 2
module kits.
EK-T8X00-CL.A01
Digital Equipment Corporation
129 Parker Street
Maynard, MA.
Dear Customer,
Congratulations on your AlphaServer system or related option purchase from
Digital Equipment Corporation. The following identifies software and
firmware requirements to support your configurations.
This letter documents specifics for:
a) AlphaServer 8200/8400 system shipments with E2062-DA REV E01/E02
or later CPU modules
b) AlphaServer 8200/8400 CPU upgrades with E2062-DA REV E01/E02 or
later CPU modules.
Actions required by the customer:
=================================
For AlphaServer 8200/8400 System shipments:
-------------------------------------------
1. The required minimum version of console, (minimum revision of V4.3) has
been loaded onto your system at the Digital factory. No action is required
if this factory loaded firmware is used. Please do not install console
firmware older than V4.3.
2. If the OpenVMS operating system has been installed at the factory,
patches have been applied. If this system will be run with OpenVMS from a
different system disk, patches will need to be applied to that system disk.
3. No patches are required for the Digital UNIX operating system.
4. As a backup to the factory loaded software, a media kit has been included
with your shipment.
For AlphaServer 8200/8400 CPU add-ons and SMP Upgrades:
-------------------------------------------------------
A combination of minimum system console and VMS patch are required:
1. Ensure console is at minimum revision 4.3. If an
upgrade is needed, follow the instructions below
for upgrading console.
2. If the system is running the OpenVMS operating system,
a patch is required. These patches are specific to
versions 6.2-1H3 and 7.1. The appropriate patch will
need to be loaded and installed. See the instructions
below for details.
3. If the system is running the Digital UNIX operating
system, no operating system patches are required.
The problem being addressed:
============================
AlphaServer 8200/8400 CPU modules E2062-DA, revision E01/E02 or later,
include a newer revision of the Alpha 21164 CPU chip.
Console firmware V4.2 or earlier does not correctly initialize the cache
when it detects the newer Alpha21164 CPU chip.
Without the operating system patch, a problem arises under OpenVMS if a
AlphaServer 8x00 system includes a mixture of old and new revisions of the
Alpha21164 CPU chip. OpenVMS does not recognize that the CPUs are
compatible, and so it does not start some or all of the secondary CPUs in
SMP mode.
The correct combination of console firmware and OpenVMS patches resolves
these problems.
Installing the correct console code:
====================================
If this letter accompanies a system shipment, the correct version of console
code has been installed in all CPUs in the system. Please do not install an
older version.
If this letter accompanies a CPU module shipment, the new module(s) contain
the current version of console firmware. Please ensure that the firmware on
the existing CPUs is the same as on the new CPUs before installing the new
CPU module(s). The enclosed firmware CD contains the current version of
console code. Simply load the CD into the CD-ROM reader and boot it.
Installing the OpenVMS patches
==============================
If this letter accompanies a system shipment, the required patches have been
pre-installed in the factory installed software. If the system will be run
using a different system disk, the OpenVMS patches must be installed on that
system disk.
If this letter accompanies a CPU module shipment, the patches must be
installed into the OpenVMS operating system in order for all CPUs to be
started correctly in SMP mode.
The required OpenVMS patches are on the enclosed OpenVMS Patches CD. Mount
the CD under OpenVMS. Copy the files to the system disk, and install the
patches following the procedure in the included .TXT file.
Sincerely,
Jim Coleman, AlphaServer 8200/8400 Engineering Program Manager
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