Click here to close now.


Microservices Expo Authors: Liz McMillan, Pat Romanski, Carmen Gonzalez, Elizabeth White, Ian Khan

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 (and a pretty good overview on 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 currently a Senior Solutions Architect at StackIQ, Inc. He is also working with Mesamundi on D20PRO, and is a member of the Stacki Open Source project. He has experience in application development, architecture, infrastructure, technical writing, 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.

@MicroservicesExpo Stories
In his General Session at DevOps Summit, Asaf Yigal, Co-Founder & VP of Product at, explored the value of Kibana 4 for log analysis and provided a hands-on tutorial on how to set up Kibana 4 and get the most out of Apache log files. He examined three use cases: IT operations, business intelligence, and security and compliance. Asaf Yigal is co-founder and VP of Product at log analytics software company In the past, he was co-founder of social-trading platform Currensee, which...
Discussions of cloud computing have evolved in recent years from a focus on specific types of cloud, to a world of hybrid cloud, and to a world dominated by the APIs that make today's multi-cloud environments and hybrid clouds possible. In this Power Panel at 17th Cloud Expo, moderated by Conference Chair Roger Strukhoff, panelists addressed the importance of customers being able to use the specific technologies they need, through environments and ecosystems that expose their APIs to make true ...
With major technology companies and startups seriously embracing IoT strategies, now is the perfect time to attend @ThingsExpo 2016 in New York and Silicon Valley. Learn what is going on, contribute to the discussions, and ensure that your enterprise is as "IoT-Ready" as it can be! Internet of @ThingsExpo, taking place Nov 3-5, 2015, at the Santa Clara Convention Center in Santa Clara, CA, is co-located with 17th Cloud Expo and will feature technical sessions from a rock star conference faculty ...
Internet of @ThingsExpo, taking place June 7-9, 2016 at Javits Center, New York City and Nov 1-3, 2016, at the Santa Clara Convention Center in Santa Clara, CA, is co-located with the 18th International @CloudExpo and will feature technical sessions from a rock star conference faculty and the leading industry players in the world and ThingsExpo New York Call for Papers is now open.
Growth hacking is common for startups to make unheard-of progress in building their business. Career Hacks can help Geek Girls and those who support them (yes, that's you too, Dad!) to excel in this typically male-dominated world. Get ready to learn the facts: Is there a bias against women in the tech / developer communities? Why are women 50% of the workforce, but hold only 24% of the STEM or IT positions? Some beginnings of what to do about it! In her Day 2 Keynote at 17th Cloud Expo, San...
There are over 120 breakout sessions in all, with Keynotes, General Sessions, and Power Panels adding to three days of incredibly rich presentations and content. Join @ThingsExpo conference chair Roger Strukhoff (@IoT2040), June 7-9, 2016 in New York City, for three days of intense 'Internet of Things' discussion and focus, including Big Data's indespensable role in IoT, Smart Grids and Industrial Internet of Things, Wearables and Consumer IoT, as well as (new) IoT's use in Vertical Markets.
The Internet of Things (IoT) is growing rapidly by extending current technologies, products and networks. By 2020, Cisco estimates there will be 50 billion connected devices. Gartner has forecast revenues of over $300 billion, just to IoT suppliers. Now is the time to figure out how you’ll make money – not just create innovative products. With hundreds of new products and companies jumping into the IoT fray every month, there’s no shortage of innovation. Despite this, McKinsey/VisionMobile data...
Just over a week ago I received a long and loud sustained applause for a presentation I delivered at this year’s Cloud Expo in Santa Clara. I was extremely pleased with the turnout and had some very good conversations with many of the attendees. Over the next few days I had many more meaningful conversations and was not only happy with the results but also learned a few new things. Here is everything I learned in those three days distilled into three short points.
One of the most important tenets of digital transformation is that it’s customer-driven. In fact, the only reason technology is involved at all is because today’s customers demand technology-based interactions with the companies they do business with. It’s no surprise, therefore, that we at Intellyx agree with Patrick Maes, CTO, ANZ Bank, when he said, “the fundamental element in digital transformation is extreme customer centricity.” So true – but note the insightful twist that Maes adde...
Using any programming framework to the fullest extent possible first requires an understanding of advanced software architecture concepts. While writing a little client-side JavaScript does not necessarily require as much consideration when designing a scalable software architecture, the evolution of tools like Node.js means that you could be facing large code bases that must be easy to maintain.
As organizations realize the scope of the Internet of Things, gaining key insights from Big Data, through the use of advanced analytics, becomes crucial. However, IoT also creates the need for petabyte scale storage of data from millions of devices. A new type of Storage is required which seamlessly integrates robust data analytics with massive scale. These storage systems will act as “smart systems” provide in-place analytics that speed discovery and enable businesses to quickly derive meaningf...
DevOps is about increasing efficiency, but nothing is more inefficient than building the same application twice. However, this is a routine occurrence with enterprise applications that need both a rich desktop web interface and strong mobile support. With recent technological advances from Isomorphic Software and others, rich desktop and tuned mobile experiences can now be created with a single codebase – without compromising functionality, performance or usability. In his session at DevOps Su...
You may have heard about the pets vs. cattle discussion – a reference to the way application servers are deployed in the cloud native world. If an application server goes down it can simply be dropped from the mix and a new server added in its place. The practice so far has mostly been applied to application deployments. Management software on the other hand is treated in a very special manner. Dedicated resources are set aside to run the management software components and several alerting syst...
It's been a busy time for tech's ongoing infatuation with containers. Amazon just announced EC2 Container Registry to simply container management. The new Azure container service taps into Microsoft's partnership with Docker and Mesosphere. You know when there's a standard for containers on the table there's money on the table, too. Everyone is talking containers because they reduce a ton of development-related challenges and make it much easier to move across production and testing environm...
People want to get going with DevOps or Continuous Delivery, but need a place to start. Others are already on their way, but need some validation of their choices. A few months ago, I published the first volume of DevOps and Continuous Delivery reference architectures which has now been viewed over 50,000 times on SlideShare (it's free to registration required). Three things helped people in the deck: (1) the reference architectures, (2) links to the sources for each architectur...
Continuous processes around the development and deployment of applications are both impacted by -- and a benefit to -- the Internet of Things trend. To help better understand the relationship between DevOps and a plethora of new end-devices and data please welcome Gary Gruver, consultant, author and a former IT executive who has led many large-scale IT transformation projects, and John Jeremiah, Technology Evangelist at Hewlett Packard Enterprise (HPE), on Twitter at @j_jeremiah. The discussion...
Hiring the wrong candidate can cost a company hundreds of thousands of dollars, and result in lost profit and productivity during the search for a replacement. In fact, the Harvard Business Review has found that as much as 80 percent of turnover is caused by bad hiring decisions. But when your organization has implemented DevOps, the job is about more than just technical chops. It’s also about core behaviors: how they work with others, how they make decisions, and how those decisions translate t...
In today's enterprise, digital transformation represents organizational change even more so than technology change, as customer preferences and behavior drive end-to-end transformation across lines of business as well as IT. To capitalize on the ubiquitous disruption driving this transformation, companies must be able to innovate at an increasingly rapid pace. Traditional approaches for driving innovation are now woefully inadequate for keeping up with the breadth of disruption and change facin...
The Internet of Things is clearly many things: data collection and analytics, wearables, Smart Grids and Smart Cities, the Industrial Internet, and more. Cool platforms like Arduino, Raspberry Pi, Intel's Galileo and Edison, and a diverse world of sensors are making the IoT a great toy box for developers in all these areas. In this Power Panel at @ThingsExpo, moderated by Conference Chair Roger Strukhoff, panelists discussed what things are the most important, which will have the most profound...
PubNub has announced the release of BLOCKS, a set of customizable microservices that give developers a simple way to add code and deploy features for realtime apps.PubNub BLOCKS executes business logic directly on the data streaming through PubNub’s network without splitting it off to an intermediary server controlled by the customer. This revolutionary approach streamlines app development, reduces endpoint-to-endpoint latency, and allows apps to better leverage the enormous scalability of PubNu...