Welcome!

AJAX & REA Authors: Liz McMillan, Elizabeth White, David H Deans, Pat Romanski, Scott Hirsch

Related Topics: Virtualization, SOA & WOA, Cloud Expo, Security, Big Data Journal, SDN Journal

Virtualization: Article

Bare Metal Blog: Quality Is Systemic, or It Is Not

In all critical systems the failure of even one piece can have catastrophic results for the user

February 5, 2013

BareMetalBlog talking about quality testing of hardware, in all its forms. F5 does a great job in this space.

For those of you new to the Bare Metal Blog series, find them all right here.

In all critical systems – from home heating units to military firearms – the failure of even one piece can have catastrophic results for the user. While it is unlikely that the failure of an ADC is going to be quite so catastrophic, it can certainly make IT staff’s day(s) terrible and cost the organization a fortune in lost revenue. That’s not to mention the problems that downtime’s impact on an organizations’ brand can have over the longer term. It is actually pretty scary to ponder the loss of any core system, but one that acts as a gateway and scaling factor for remote employee workload and/or customer access is even higher on the list of Things To Be Avoided ™.

In general, if you think about it the number of hardware failures out there is relatively minimal. There are a ton of pieces of network gear doing their thing every day, and yes, there is the occasional outage, but if you consider the number of devices NOT going down on a given day, the failure rate is very tiny.

Still, no one wants to be in that tiny percentage any more than they absolutely must. Hardware breaks, and will always do so, it is the nature of electronic and mechanical things. But we should ask more questions of our vendors to make certain they’re doing all that they can to keep the chances of their device breaking during their otherwise useful lifetime to a minimum.

For an example of doing it right, we’ll talk a bit about the lengths that F5 goes to in an attempt to make devices as reliable as possible from an  electro-mechanical perspective. While I am an F5 employee, I will note that there is no doubt that F5 gear is highly reliable. It was known for quality before I came to F5, and I have not heard anything since joining that would change that impression. So I use F5 because (a) I am aware of the steps we take as an organization and (b) because our hardware testing is an example of doing it right.

And of course, there are things I can’t tell you, and things that we just will not have room to delve into very deeply in this overview blog. I am considering extending the Bare Metal Blog series to include (among other things) more detail about those parts that I would want to know more about if I were a reader, but for this blog, we’re going to skim so there is space to cover everything without making the blog so long you don’t read to the end.

I admit it, I’ve talked to a lot of companies about testing over the years, and can’t recall a vendor that did a more thorough job – though I can think of a few whose record in the field says they probably have a similar program. So let’s look at some of the quality testing done on hardware.

Parts are not just parts.
An ADC, like any computerized system, is a complex beast. There is a lot going on and the quality of the weakest link is the piece that sets the life expectancy and out-of-the-box quality standards for the overall product. As such there are some detailed parts and subassembly tests that gear must go through.

For F5, these tests include:

  • Signal Integrity Tests to test for signal degradation between parts/subsystems.
  • BIOS Test Suites to validate that BIOS performs as expected and handles exception cases reliably.
  • Software Design Verification Testing to detect and eliminate software quality issues early in the development process.
  • Sub- Assembly Tests to verify correct subsystem performance and quality.
  • FPGA System Validation Tests determines that the FPGA design and hardware perform as expected.
  • Automated Optical Inspection used on the PCB production line to prevent and detect defects.
  • Automated X-Ray Inspection takes 3D slices of an assembled circuit board to prevent and detect defects.
  • In-Circuit Test using a series of probes to test the populated circuit board with power applied to detect defects.
  • Flying Probe uses a “golden board” (perfect sample) to compare against a newly produced board to verify there are no defects.

Now that’s a lot of testing, though I have to admit I’m still learning about the testing process, there may well be more. But you’ll note that some things aren’t immediately called out here – like items picked from suppliers, which could be caught in some of these tests but might not  either. That is because supplier quality standards are separate from actual testing, and require that suppliers whose parts make it into F5 gear are up to standard.

Supply demands
So what do we, as an organization, require from a quality perspective of those who wish to be our suppliers? Here’s a list. This list I KNOW isn’t complete, because I pared it down for the purposes of this blog. I think you’ll get the idea from what’s here though.

  • All assembly suppliers are ISO9000 and 140001 certified.
  • Suppliers assemble and test their products to F5 specifications.
  • Suppliers are monitored with closed loop performance metrics including delivery and quality.
  • Formal Supplier Corrective Action Response program – when a fault is determined in supplier quality, a formal system to quickly address the issue.
  • Quarterly reviews with senior management utilizing a formal supplier scorecard to evaluate supplier quality, stability, and more.

The biggest one in the list, IMO, is that suppliers assemble and test product to F5 specifications. Their part is going in our box, but our name is going on it. F5 has a vested interest in protecting that name, so setting the standards by which the suppliers put together and test the product they are supplying is huge. After all, many suppliers are building tiny little subsystems for inside an F5 device, so holding them to F5 standards makes the whole stronger.

By way of example, we require the more reliable but more expensive version of capacitors from our suppliers. For a bit of background on the problem, there is an excellent article on hardwaresecrets.com (and a pretty good overview on wikipedia.com) about capacitors. By demanding that our suppliers use better quality components, the overall life expectancy of our hardware is higher, meaning you get less calls in the middle of the night.

The whole is different than the sum of the parts
While an organization can test parts until the sun rises in the west, that will not guarantee the quality of the overall product. And in the end, it is the overall product that a vendor sells. As such, manufacturers generally (and F5 specifically) keep an entire suite of whole-product tests on-hand for product quality assessment. Here are some of them used at F5.

  • Mechanical Testing Test the construction of the system by  applying shock, drop, vibe, repetitive insertion/extractions, and more.
  • Highly Accelerated Life Testing -  Heat and vibration are used to determine the quality and operational limits of the device. The goal is to simulate years of use in a manageable timeframe.
  • Environmental Stress Screening – Expose the device to extremes of environment, from temperature to voltage.
  • MFG Test Suite System Stress testing - turn everything on, Reboot, Power Cycle, et cetera. By way of example, we cycle power up to 10,000 times during this testing.
  • On-Going Reliability Testing - The products currently in the manufacturing line are randomly picked and then put in a burn-in chamber which then test the device at elevated temperature.
  • Post Pack out Audit – Pull random samples from our finished good inventory to verify quality.

That’s a lot of testing, and it is not anywhere near all that F5 does to validate a box. For example, while software testing got a hat-tip at the component level, our Traffic Management Operating System (TMOS) has a completely separate set of testing, validation, and QA processes that are not listed here because this is the Bare Metal Blog. Maybe at some point in the future I’ll do a series like Bare Metal Blog on our software. That would be interesting for me, hopefully for you also.

It’s not over when it’s over
The entire time that Lori and I were application developers, there was a party to celebrate every time we finished a major piece of software. From an evening out with the team when our tax prep software shipped to a bottle of champagne on the roof of an AutoDesk office building when AutoCAD Map shipped, we always got to relax and enjoy it a bit.

While our hardware dev teams get something similar, our hardware test teams don’t pack up the gear and call it a product. For the entire lifecycle of an F5 box – from first prototype to End of Life – our test team does continuous testing to monitor and improve the quality of the product. Unlike most of what you will find in this blog, that is pretty unique to F5. Other companies do it, but unlike ISO certification or HALT testing, continuous testing is not accepted as a mandatory part of product engineering in the computing space. F5 does this because it makes the most sense. From variations in quality of chips to suppliers changing their suppliers, things change over the production of a product, and F5 feels it is important to overall quality to stay on top of that fact. This system also allows for continuous improvement of the product over its lifecycle.

One of the many reasons I think F5 is a great company. I have twice run into scenarios that involved a vendor who did not do this type of testing, and it cost me. Once was as a reviewer, which means it was worse for the vendor than for me, and once as an IT manager, which means it was worse for me than the vendor. I would suggest you start asking your vendors about lifetime testing, because a manufacturing or supplier change can impact the reliability of the gear. And if it does, either they catch it, or you could be walking into a nightmare. The perfect example (because so many of us had to deal with it) was a huge multinational selling systems with “DeskStar” disks that we all now lovingly call “Death Star” disks.

You can rely on it
This process is a proactive investment by F5 in your satisfaction. While you might think “doesn’t all that testing – particularly when continuous testing occurs over the breadth of devices you sell – cost a lot of money?”, the answer is “nowhere near as much as having to visit every device of model X and repair it, nowhere near as much as the loss of business persistent quality issues generates”. And it is true. We truly care about your satisfaction and the reliability of your network, but when it comes down to it, that caring is based upon enlightened self interest. The net result though is devices you can trust to just keep going.

I know, we have one in our basement from before we came to F5, It’s old and looks funny next to our shiny newer one. But it still works. It’s EOL’d, so it isn’t getting any better, and when it breaks it’s done, but the device is nearly a decade old, and still operates as originally advertised.

If only our laptops could do that.

More Stories By Don MacVittie

Don MacVittie is Founder of Ingrained Technology, LLC, specializing in Development, Devops, and Cloud Strategy. Previously, he was a Technical Marketing Manager at F5 Networks. As an industry veteran, MacVittie has extensive programming experience along with project management, IT management, and systems/network administration expertise.

Prior to joining F5, MacVittie was a Senior Technology Editor at Network Computing, where he conducted product research and evaluated storage and server systems, as well as development and outsourcing solutions. He has authored numerous articles on a variety of topics aimed at IT professionals. MacVittie holds a B.S. in Computer Science from Northern Michigan University, and an M.S. in Computer Science from Nova Southeastern University.

@CloudExpo Stories
We are all here because we are sold on the transformative promise of The Cloud. But what good is all of this ephemeral, on-demand infrastructure if your usage doesn't actually improve the agility and speed of your business? How must Operations adapt in order to avoid stifling your Cloud initiative? In his session at DevOps Summit, Damon Edwards, co-founder and managing partner of the DTO Solutions, will highlight the successful organizational, process, and tooling patterns of high-performing c...
The definition of IoT is not new, in fact it’s been around for over a decade. What has changed is the public's awareness that the technology we use on a daily basis has caught up on the vision of an always on, always connected world. If you look into the details of what comprises the IoT, you’ll see that it includes everything from cloud computing, Big Data analytics, “Things,” Web communication, applications, network, storage, etc. It is essentially including everything connected online from ha...
Software-driven innovation is becoming a primary approach to how businesses create and deliver new value to customers. A survey of 400 business and IT executives by the IBM Institute for Business Value showed businesses that are more effective at software delivery are also more profitable than their peers nearly 70 percent of the time (1). DevOps provides a way for businesses to remain competitive, applying lean and agile principles to software development to speed the delivery of software that ...
Docker offers a new, lightweight approach to application portability. Applications are shipped using a common container format and managed with a high-level API. Their processes run within isolated namespaces that abstract the operating environment independently of the distribution, versions, network setup, and other details of this environment. This "containerization" has often been nicknamed "the new virtualization." But containers are more than lightweight virtual machines. Beyond their small...
The move in recent years to cloud computing services and architectures has added significant pace to the application development and deployment environment. When enterprise IT can spin up large computing instances in just minutes, developers can also design and deploy in small time frames that were unimaginable a few years ago. The consequent move toward lean, agile, and fast development leads to the need for the development and operations sides to work very closely together. Thus, DevOps become...
Cloud Expo 2014 TV commercials will feature @ThingsExpo, which was launched in June, 2014 at New York City's Javits Center as the largest 'Internet of Things' event in the world.

ARMONK, N.Y., Nov. 20, 2014 /PRNewswire/ --  IBM (NYSE: IBM) today announced that it is bringing a greater level of control, security and flexibility to cloud-based application development and delivery with a single-tenant version of Bluemix, IBM's

An entirely new security model is needed for the Internet of Things, or is it? Can we save some old and tested controls for this new and different environment? In his session at @ThingsExpo, New York's at the Javits Center, Davi Ottenheimer, EMC Senior Director of Trust, reviewed hands-on lessons with IoT devices and reveal a new risk balance you might not expect. Davi Ottenheimer, EMC Senior Director of Trust, has more than nineteen years' experience managing global security operations and asse...
The major cloud platforms defy a simple, side-by-side analysis. Each of the major IaaS public-cloud platforms offers their own unique strengths and functionality. Options for on-site private cloud are diverse as well, and must be designed and deployed while taking existing legacy architecture and infrastructure into account. Then the reality is that most enterprises are embarking on a hybrid cloud strategy and programs. In this Power Panel at 15th Cloud Expo (http://www.CloudComputingExpo.com...
Explosive growth in connected devices. Enormous amounts of data for collection and analysis. Critical use of data for split-second decision making and actionable information. All three are factors in making the Internet of Things a reality. Yet, any one factor would have an IT organization pondering its infrastructure strategy. How should your organization enhance its IT framework to enable an Internet of Things implementation? In his session at Internet of @ThingsExpo, James Kirkland, Chief Ar...
Leysin American School is an exclusive, private boarding school located in Leysin, Switzerland. Leysin selected an OpenStack-powered, private cloud as a service to manage multiple applications and provide development environments for students across the institution. Seeking to meet rigid data sovereignty and data integrity requirements while offering flexible, on-demand cloud resources to users, Leysin identified OpenStack as the clear choice to round out the school's cloud strategy. Additional...
The security devil is always in the details of the attack: the ones you've endured, the ones you prepare yourself to fend off, and the ones that, you fear, will catch you completely unaware and defenseless. The Internet of Things (IoT) is nothing if not an endless proliferation of details. It's the vision of a world in which continuous Internet connectivity and addressability is embedded into a growing range of human artifacts, into the natural world, and even into our smartphones, appliances, a...
Technology is enabling a new approach to collecting and using data. This approach, commonly referred to as the "Internet of Things" (IoT), enables businesses to use real-time data from all sorts of things including machines, devices and sensors to make better decisions, improve customer service, and lower the risk in the creation of new revenue opportunities. In his General Session at Internet of @ThingsExpo, Dave Wagstaff, Vice President and Chief Architect at BSQUARE Corporation, discuss the ...
"BSQUARE is in the business of selling software solutions for smart connected devices. It's obvious that IoT has moved from being a technology to being a fundamental part of business, and in the last 18 months people have said let's figure out how to do it and let's put some focus on it, " explained Dave Wagstaff, VP & Chief Architect, at BSQUARE Corporation, in this SYS-CON.tv interview at @ThingsExpo, held Nov 4-6, 2014, at the Santa Clara Convention Center in Santa Clara, CA.
The 4th International DevOps Summit, co-located with16th International Cloud Expo – being held June 9-11, 2015, at the Javits Center in New York City, NY – announces that its Call for Papers is now open. Born out of proven success in agile development, cloud computing, and process automation, DevOps is a macro trend you cannot afford to miss. From showcase success stories from early adopters and web-scale businesses, DevOps is expanding to organizations of all sizes, including the world's large...
Verizon Enterprise Solutions is simplifying the cloud-purchasing experience for its clients, with the launch of Verizon Cloud Marketplace, a key foundational component of the company's robust ecosystem of enterprise-class technologies. The online storefront will initially feature pre-built cloud-based services from AppDynamics, Hitachi Data Systems, Juniper Networks, PfSense and Tervela. Available globally to enterprises using Verizon Cloud, Verizon Cloud Marketplace provides a one-stop shop fo...
"Our premise is Docker is not enough. That's not a bad thing - we actually love Docker. At ActiveState all our products are based on open source technology and Docker is an up-and-coming piece of open source technology," explained Bart Copeland, President & CEO of ActiveState Software, in this SYS-CON.tv interview at DevOps Summit at Cloud Expo®, held Nov 4-6, 2014, at the Santa Clara Convention Center in Santa Clara, CA.
DevOps Summit 2015 New York, co-located with the 16th International Cloud Expo - to be held June 9-11, 2015, at the Javits Center in New York City, NY - announces that it is now accepting Keynote Proposals. The widespread success of cloud computing is driving the DevOps revolution in enterprise IT. Now as never before, development teams must communicate and collaborate in a dynamic, 24/7/365 environment. There is no time to wait for long development cycles that produce software that is obsolete...
Infor has announced a new feature Infor CloudSuite™ Aerospace & Defense (A&D) to aid compliance with International Traffic in Arms Regulations (ITAR). The ITAR function will serve as a complementary function for new or existing Infor CloudSuite A&D customers, to facilitate compliance for Infor customers that are creating a US defense article or performing a US defense service and wish to benefit from cloud-services. The ITAR regulation serves to manage handling and access requirements for dat...
What do a firewall and a fortress have in common? They are no longer strong enough to protect the valuables housed inside. Like the walls of an old fortress, the cracks in the firewall are allowing the bad guys to slip in - unannounced and unnoticed. By the time these thieves get in, the damage is already done and the network is already compromised. Intellectual property is easily slipped out the back door leaving no trace of forced entry. If we want to reign in on these cybercriminals, it's hig...