© Copyright Rochester Electronics

Page 4

June 2011

 

Some testing can give a reasonable assurance about the credibility of a device, but the counterfeiters know and

understand the capabilities of the test methods and are continually working on ways to deceive purchasers.

True, reliable testing of components can be done only by experienced engineers using the original manufacturer’s

equipment and test protocols; this, of course, can be done only with authorisation of the original manufacturer,

and most test houses do not work closely with original manufacturers.

Here are some typical tests and test costs from these test houses:

•

External visual inspection and paperwork check – more than $50 per hour

•

Marking permanence – more than $50 per hour

•

Scanning acoustic microscopy – more than $800 per hour

•

XRF check of terminations – more than $500 per test

•

X-ray check for internal – more than $500 per test

•

De-cap inspection – more than $1,000 per test

•

Electrical testing – more than $50 per test plus nonrecurring engineering (NRE) costs for developing

and/or adjusting the test programme

Sample NRE costs and additional costs:

o

$4,000 for simple logic devices

o

More than $30,000 for complex VLSI logic, processors, and mixed signal devices

o

Cost of any extra hardware/load boards

Because counterfeiters indiscriminately mix good and counterfeit parts together in the same lot, all components in

a lot must be tested, at an expense that adds significantly to the price of components.

There are also semiconductor-related costs incurred by an equipment manufacturer that are not so visible or well

understood:

•

Purchasing staff must be trained about the dangers of counterfeit devices.

•

Goods inwards staff must be trained to check incoming material, especially product sourced from non-

authorised sources.

•

Purchasing controls and protocols must be established and monitored. This may include limiting the

sources of supply.

•

When a counterfeit lot is detected, either by a distributor, test house, or at incoming inspection, there is

likely to be a loss of manufacturing time and output while replacement components are sourced.

•

If a counterfeit part does get through to production, the costs to the equipment manufacturer increase

exponentially:

o

10 times the original device price if the counterfeit is found at board test

o

100 times the original device price if the counterfeit is found at equipment final test

o

1000 times the original device price if the counterfeit is found after the equipment is in use

It should be remembered that the identified test costs apply only to purchases from non-authorised sources.

However, due to concern about supply, the costs of training personnel, the extra vigilance, and the need for test

house services or in-house test equipment, additional expenses are being imposed throughout the industry.

 

Cost to the Electronics Equipment Users

 

Counterfeit components cause extra expenses throughout all levels of the electronics industry. Equipment users

are no exception:

•

Semiconductors for repairs and scheduled maintenance must be purchased with the same care and

attention expended by the original equipment manufacturers when they purchased the original

components.