Click here to close now.

Welcome!

Big Data Journal Authors: Liz McMillan, Pat Romanski, Marty Puranik, Carmen Gonzalez, Michael Jannery

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.

@BigDataExpo Stories
The Workspace-as-a-Service (WaaS) market will grow to $6.4B by 2018. In his session at 16th Cloud Expo, Seth Bostock, CEO of IndependenceIT, will begin by walking the audience through the evolution of Workspace as-a-Service, where it is now vs. where it going. To look beyond the desktop we must understand exactly what WaaS is, who the users are, and where it is going in the future. IT departments, ISVs and service providers must look to workflow and automation capabilities to adapt to growing ...
As organizations shift toward IT-as-a-service models, the need for managing and protecting data residing across physical, virtual, and now cloud environments grows with it. CommVault can ensure protection &E-Discovery of your data – whether in a private cloud, a Service Provider delivered public cloud, or a hybrid cloud environment – across the heterogeneous enterprise. In his session at 16th Cloud Expo, Randy De Meno, Chief Technologist - Windows Products and Microsoft Partnerships, will disc...
Hadoop as a Service (as offered by handful of niche vendors now) is a cloud computing solution that makes medium and large-scale data processing accessible, easy, fast and inexpensive. In his session at Big Data Expo, Kumar Ramamurthy, Vice President and Chief Technologist, EIM & Big Data, at Virtusa, will discuss how this is achieved by eliminating the operational challenges of running Hadoop, so one can focus on business growth. The fragmented Hadoop distribution world and various PaaS soluti...
One of the biggest impacts of the Internet of Things is and will continue to be on data; specifically data volume, management and usage. Companies are scrambling to adapt to this new and unpredictable data reality with legacy infrastructure that cannot handle the speed and volume of data. In his session at @ThingsExpo, Don DeLoach, CEO and president of Infobright, will discuss how companies need to rethink their data infrastructure to participate in the IoT, including: Data storage: Understand...
Since 2008 and for the first time in history, more than half of humans live in urban areas, urging cities to become “smart.” Today, cities can leverage the wide availability of smartphones combined with new technologies such as Beacons or NFC to connect their urban furniture and environment to create citizen-first services that improve transportation, way-finding and information delivery. In her session at @ThingsExpo, Laetitia Gazel-Anthoine, CEO of Connecthings, will focus on successful use c...
The true value of the Internet of Things (IoT) lies not just in the data, but through the services that protect the data, perform the analysis and present findings in a usable way. With many IoT elements rooted in traditional IT components, Big Data and IoT isn’t just a play for enterprise. In fact, the IoT presents SMBs with the prospect of launching entirely new activities and exploring innovative areas. CompTIA research identifies several areas where IoT is expected to have the greatest impac...
There are many considerations when moving applications from on-premise to cloud. It is critical to understand the benefits and also challenges of this migration. A successful migration will result in lower Total Cost of Ownership, yet offer the same or higher level of robustness. In his session at 15th Cloud Expo, Michael Meiner, an Engineering Director at Oracle, Corporation, will analyze a range of cloud offerings (IaaS, PaaS, SaaS) and discuss the benefits/challenges of migrating to each of...
Cloud data governance was previously an avoided function when cloud deployments were relatively small. With the rapid adoption in public cloud – both rogue and sanctioned, it’s not uncommon to find regulated data dumped into public cloud and unprotected. This is why enterprises and cloud providers alike need to embrace a cloud data governance function and map policies, processes and technology controls accordingly. In her session at 15th Cloud Expo, Evelyn de Souza, Data Privacy and Compliance...
Containers and microservices have become topics of intense interest throughout the cloud developer and enterprise IT communities. Accordingly, attendees at the upcoming 16th Cloud Expo at the Javits Center in New York June 9-11 will find fresh new content in a new track called PaaS | Containers & Microservices Containers are not being considered for the first time by the cloud community, but a current era of re-consideration has pushed them to the top of the cloud agenda. With the launch ...
Roberto Medrano, Executive Vice President at SOA Software, had reached 30,000 page views on his home page - http://RobertoMedrano.SYS-CON.com/ - on the SYS-CON family of online magazines, which includes Cloud Computing Journal, Internet of Things Journal, Big Data Journal, and SOA World Magazine. He is a recognized executive in the information technology fields of SOA, internet security, governance, and compliance. He has extensive experience with both start-ups and large companies, having been ...
The industrial software market has treated data with the mentality of “collect everything now, worry about how to use it later.” We now find ourselves buried in data, with the pervasive connectivity of the (Industrial) Internet of Things only piling on more numbers. There’s too much data and not enough information. In his session at @ThingsExpo, Bob Gates, Global Marketing Director, GE’s Intelligent Platforms business, to discuss how realizing the power of IoT, software developers are now focu...
Operational Hadoop and the Lambda Architecture for Streaming Data Apache Hadoop is emerging as a distributed platform for handling large and fast incoming streams of data. Predictive maintenance, supply chain optimization, and Internet-of-Things analysis are examples where Hadoop provides the scalable storage, processing, and analytics platform to gain meaningful insights from granular data that is typically only valuable from a large-scale, aggregate view. One architecture useful for capturing...
SYS-CON Events announced today that Vitria Technology, Inc. will exhibit at SYS-CON’s @ThingsExpo, which will take place on June 9-11, 2015, at the Javits Center in New York City, NY. Vitria will showcase the company’s new IoT Analytics Platform through live demonstrations at booth #330. Vitria’s IoT Analytics Platform, fully integrated and powered by an operational intelligence engine, enables customers to rapidly build and operationalize advanced analytics to deliver timely business outcomes ...
SYS-CON Events announced today that Open Data Centers (ODC), a carrier-neutral colocation provider, will exhibit at SYS-CON's 16th International Cloud Expo®, which will take place June 9-11, 2015, at the Javits Center in New York City, NY. Open Data Centers is a carrier-neutral data center operator in New Jersey and New York City offering alternative connectivity options for carriers, service providers and enterprise customers.
Thanks to Docker, it becomes very easy to leverage containers to build, ship, and run any Linux application on any kind of infrastructure. Docker is particularly helpful for microservice architectures because their successful implementation relies on a fast, efficient deployment mechanism – which is precisely one of the features of Docker. Microservice architectures are therefore becoming more popular, and are increasingly seen as an interesting option even for smaller projects, instead of bein...
The explosion of connected devices / sensors is creating an ever-expanding set of new and valuable data. In parallel the emerging capability of Big Data technologies to store, access, analyze, and react to this data is producing changes in business models under the umbrella of the Internet of Things (IoT). In particular within the Insurance industry, IoT appears positioned to enable deep changes by altering relationships between insurers, distributors, and the insured. In his session at @Things...
Even as cloud and managed services grow increasingly central to business strategy and performance, challenges remain. The biggest sticking point for companies seeking to capitalize on the cloud is data security. Keeping data safe is an issue in any computing environment, and it has been a focus since the earliest days of the cloud revolution. Understandably so: a lot can go wrong when you allow valuable information to live outside the firewall. Recent revelations about government snooping, along...
In his session at DevOps Summit, Tapabrata Pal, Director of Enterprise Architecture at Capital One, will tell a story about how Capital One has embraced Agile and DevOps Security practices across the Enterprise – driven by Enterprise Architecture; bringing in Development, Operations and Information Security organizations together. Capital Ones DevOpsSec practice is based upon three "pillars" – Shift-Left, Automate Everything, Dashboard Everything. Within about three years, from 100% waterfall, C...
SYS-CON Media announced that IBM, which offers the world’s deepest portfolio of technologies and expertise that are transforming the future of work, has launched ad campaigns on SYS-CON’s numerous online magazines such as Cloud Computing Journal, Virtualization Journal, SOA World Magazine, and IoT Journal. IBM’s campaigns focus on vendors in the technology marketplace, the future of testing, Big Data and analytics, and mobile platforms.
The explosion of connected devices / sensors is creating an ever-expanding set of new and valuable data. In parallel the emerging capability of Big Data technologies to store, access, analyze, and react to this data is producing changes in business models under the umbrella of the Internet of Things (IoT). In particular within the Insurance industry, IoT appears positioned to enable deep changes by altering relationships between insurers, distributors, and the insured. In his session at @Things...