Layout-aware scan chain synthesis for improved path delay fault coverage

Path delay fault testing has become increasingly important due to higher clock rates and higher process variability caused by shrinking geometries. Achieving high-coverage path delay fault testing requires the application of scan justified test vector pairs, coupled with careful ordering of the scan flip-flops and/or insertion of dummy flip-flops in the scan chain. Previous works on scan synthesis for path delay fault testing using scan shifting have focused exclusively on maximizing fault coverage and/or minimizing the number of dummy flip-flops, but have disregarded the scan wirelength overhead. In this paper we propose a layout-aware coverage-driven scan chain ordering methodology and give exact and heuristic algorithms for computing the achievable tradeoffs between path delay fault coverage and both dummy flip-flop and wirelength costs. Experimental results show that our scan chain ordering methodology yields significant improvements in path delay coverage with a very small increase in wirelength overhead compared to previous layout-driven approaches, and similar coverage with up to 25 times improvement in wirelength compared to previous layout-oblivious coverage-driven approaches.