1. Purpose and scope
Modules that are capable alone can fail in sequence. Warpage from moulding can upset bonding alignment; a clean step can attack a dielectric; heat from one step can age an earlier material; queue time between surface preparation and bonding can decide yield. The purpose of this stage is to join the modules into one flow, build complete test vehicles on it, measure them, and freeze a process baseline that qualification, the design kit and lead customers can rely on.
Full-flow test vehicles are measured for daisy chain continuity and resistance, leakage, warpage across temperature, alignment, voids and early failures, and, where the vehicles include them, die-to-die link performance. The modelling team compares extraction, warpage and thermal predictions with measurement, and the design kit team updates the assembly design rules from what the hardware shows. Quality leads a process failure mode and effects analysis of the whole flow.
In scope: the integrated process flow, full-flow builds, test vehicle measurement data, model to hardware correlation, the process FMEA, updated rules, module control plans and the process baseline. Out of scope: the full reliability qualification, which starts on the frozen baseline in the next stage.
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