Welcome!

Machine Learning Authors: Pat Romanski, Elizabeth White, Kevin Benedict, William Schmarzo, Automic Blog

Related Topics: Containers Expo Blog, Microservices Expo, @CloudExpo, Cloud Security, @BigDataExpo, SDN Journal

Containers Expo Blog: 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, A technical advocacy and software development consultancy. He has experience in application development, architecture, infrastructure, technical writing,DevOps, and IT management. 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
Your homes and cars can be automated and self-serviced. Why can't your storage? From simply asking questions to analyze and troubleshoot your infrastructure, to provisioning storage with snapshots, recovery and replication, your wildest sci-fi dream has come true. In his session at @DevOpsSummit at 20th Cloud Expo, Dan Florea, Director of Product Management at Tintri, provided a ChatOps demo where you can talk to your storage and manage it from anywhere, through Slack and similar services with...
The financial services market is one of the most data-driven industries in the world, yet it’s bogged down by legacy CPU technologies that simply can’t keep up with the task of querying and visualizing billions of records. In his session at 20th Cloud Expo, Karthik Lalithraj, a Principal Solutions Architect at Kinetica, discussed how the advent of advanced in-database analytics on the GPU makes it possible to run sophisticated data science workloads on the same database that is housing the rich...
DevOps at Cloud Expo, taking place October 31 - November 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA, is co-located with 21st Cloud Expo and will feature technical sessions from a rock star conference faculty and the leading industry players in the world. 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 w...
Any startup has to have a clear go –to-market strategy from the beginning. Similarly, any data science project has to have a go to production strategy from its first days, so it could go beyond proof-of-concept. Machine learning and artificial intelligence in production would result in hundreds of training pipelines and machine learning models that are continuously revised by teams of data scientists and seamlessly connected with web applications for tenants and users.
"We want to show that our solution is far less expensive with a much better total cost of ownership so we announced several key features. One is called geo-distributed erasure coding, another is support for KVM and we introduced a new capability called Multi-Part," explained Tim Desai, Senior Product Marketing Manager at Hitachi Data Systems, in this SYS-CON.tv interview at 20th Cloud Expo, held June 6-8, 2017, at the Javits Center in New York City, NY.
There is a huge demand for responsive, real-time mobile and web experiences, but current architectural patterns do not easily accommodate applications that respond to events in real time. Common solutions using message queues or HTTP long-polling quickly lead to resiliency, scalability and development velocity challenges. In his session at 21st Cloud Expo, Ryland Degnan, a Senior Software Engineer on the Netflix Edge Platform team, will discuss how by leveraging a reactive stream-based protocol,...
SYS-CON Events announced today that SkyScale will exhibit at SYS-CON's 21st International Cloud Expo®, which will take place on Oct 31 – Nov 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA. SkyScale is a world-class provider of cloud-based, ultra-fast multi-GPU hardware platforms for lease to customers desiring the fastest performance available as a service anywhere in the world. SkyScale builds, configures, and manages dedicated systems strategically located in maximum-securit...
With tough new regulations coming to Europe on data privacy in May 2018, Calligo will explain why in reality the effect is global and transforms how you consider critical data. EU GDPR fundamentally rewrites the rules for cloud, Big Data and IoT. In his session at 21st Cloud Expo, Adam Ryan, Vice President and General Manager EMEA at Calligo, will examine the regulations and provide insight on how it affects technology, challenges the established rules and will usher in new levels of diligence...
As businesses adopt functionalities in cloud computing, it’s imperative that IT operations consistently ensure cloud systems work correctly – all of the time, and to their best capabilities. In his session at @BigDataExpo, Bernd Harzog, CEO and founder of OpsDataStore, presented an industry answer to the common question, “Are you running IT operations as efficiently and as cost effectively as you need to?” He then expounded on the industry issues he frequently came up against as an analyst, and ...
DX World EXPO, LLC., a Lighthouse Point, Florida-based startup trade show producer and the creator of "DXWorldEXPO® - Digital Transformation Conference & Expo" has announced its executive management team. The team is headed by Levent Selamoglu, who has been named CEO. "Now is the time for a truly global DX event, to bring together the leading minds from the technology world in a conversation about Digital Transformation," he said in making the announcement.
Internet of @ThingsExpo, taking place October 31 - November 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA, is co-located with 21st Cloud Expo and will feature technical sessions from a rock star conference faculty and the leading industry players in the world. The Internet of Things (IoT) is the most profound change in personal and enterprise IT since the creation of the Worldwide Web more than 20 years ago. All major researchers estimate there will be tens of billions devic...
What sort of WebRTC based applications can we expect to see over the next year and beyond? One way to predict development trends is to see what sorts of applications startups are building. In his session at @ThingsExpo, Arin Sime, founder of WebRTC.ventures, discussed the current and likely future trends in WebRTC application development based on real requests for custom applications from real customers, as well as other public sources of information.
"The Striim platform is a full end-to-end streaming integration and analytics platform that is middleware that covers a lot of different use cases," explained Steve Wilkes, Founder and CTO at Striim, in this SYS-CON.tv interview at 20th Cloud Expo, held June 6-8, 2017, at the Javits Center in New York City, NY.
SYS-CON Events announced today that Calligo, an innovative cloud service provider offering mid-sized companies the highest levels of data privacy and security, has been named "Bronze Sponsor" of SYS-CON's 21st International Cloud Expo ®, which will take place on Oct 31 - Nov 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA. Calligo offers unparalleled application performance guarantees, commercial flexibility and a personalised support service from its globally located cloud plat...
In his session at 20th Cloud Expo, Mike Johnston, an infrastructure engineer at Supergiant.io, discussed how to use Kubernetes to set up a SaaS infrastructure for your business. Mike Johnston is an infrastructure engineer at Supergiant.io with over 12 years of experience designing, deploying, and maintaining server and workstation infrastructure at all scales. He has experience with brick and mortar data centers as well as cloud providers like Digital Ocean, Amazon Web Services, and Rackspace. H...
SYS-CON Events announced today that Massive Networks will exhibit at SYS-CON's 21st International Cloud Expo®, which will take place on Oct 31 – Nov 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA. Massive Networks mission is simple. To help your business operate seamlessly with fast, reliable, and secure internet and network solutions. Improve your customer's experience with outstanding connections to your cloud.
FinTechs use the cloud to operate at the speed and scale of digital financial activity, but are often hindered by the complexity of managing security and compliance in the cloud. In his session at 20th Cloud Expo, Sesh Murthy, co-founder and CTO of Cloud Raxak, showed how proactive and automated cloud security enables FinTechs to leverage the cloud to achieve their business goals. Through business-driven cloud security, FinTechs can speed time-to-market, diminish risk and costs, maintain continu...
21st International Cloud Expo, taking place October 31 - November 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA, will feature technical sessions from a rock star conference faculty and the leading industry players in the world. Cloud computing is now being embraced by a majority of enterprises of all sizes. Yesterday's debate about public vs. private has transformed into the reality of hybrid cloud: a recent survey shows that 74% of enterprises have a hybrid cloud strategy. Me...
SYS-CON Events announced today that DXWorldExpo has been named “Global Sponsor” of SYS-CON's 21st International Cloud Expo, which will take place on Oct 31 – Nov 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA. Digital Transformation is the key issue driving the global enterprise IT business. Digital Transformation is most prominent among Global 2000 enterprises and government institutions.
SYS-CON Events announced today that Datera, that offers a radically new data management architecture, has been named "Exhibitor" of SYS-CON's 21st International Cloud Expo ®, which will take place on Oct 31 - Nov 2, 2017, at the Santa Clara Convention Center in Santa Clara, CA. Datera is transforming the traditional datacenter model through modern cloud simplicity. The technology industry is at another major inflection point. The rise of mobile, the Internet of Things, data storage and Big...