1.7 Counterfeit avoidance (AS5553)

Counterfeit components pose a significant risk to manufacturing integrity. A “remarked” or “blacktopped” component might pass initial functional testing but fail later in the field due to thermal mismatch or latent ESD damage, leading to recalls and reliability issues. The objective is to maintain strict prevention strategies. Counterfeit avoidance involves proactively managing sourcing hierarchies and enforcing robust validation protocols to protect the supply chain.

The sourcing hierarchy

Supply chain risk is heavily influenced by the Chain of Custody (CoC). The sourcing path determines the necessary level of inspection.

Tier 1: the secure channel (preferred)

• The Definition: The Original Component Manufacturer (OCM) direct, or a formally Franchised/Authorized Distributor (e.g. Digi-Key, Mouser, Avnet).
• The Status: Authorized.
• The Requirement: Unbroken paper traceability to the OCM. A formal Manufacturer CoC should be provided with the shipment.
• The Risk: Very Low.

Tier 2: the open market (broker/independent)

• The Definition: Non-franchised, independent distributors sourcing from global excess inventory.
• The Status: Restricted.
• The Requirement: Sourcing from Tier 2 generally requires a formal approval or waiver from Supply Chain leadership or Engineering, typically when authorized channels cannot meet production needs.
• The Risk: High. Material from the open market requires thorough verification and often destructive testing to prove authenticity.

Risk-based evidence requirements

The requirements for documentation and testing should scale based on the source’s transparency.

Risk Class	Source Type	Documentation Required	Inspection / Testing Recommendation
Class I	OCM / Authorized	Mfg CoC + Packing Slip	Standard Incoming (Verify qty, check for damage, scan labels)
Class II	Broker (Traceable)	3rd Party CoC + Trace Docs	Enhanced Visual (Microscope) & Verify Supplier Solvency
Class III	Broker (No Trace)	Invoice Only (High Risk)	Full Protocol (e.g. AS6081: X-Ray, Decap, XRF, Electrical)

Pro-Tip: Acetone swabbing (checking for “blacktopping” or laser remarking) is an effective initial test. If the top coating dissolves or the ink smears under an acetone swab, the part is highly suspect. This simple check on the receiving dock can flag issues before sending parts out for expensive lab analysis.

Sourcing & forensic validation logic

Apply a consistent validation flow to incoming lots based on their source.

Step 1: determine channel validity

• When the Source is Tier 1 Authorized:
  • Verify the printed CoC aligns with the physical reel labels, then accept the lot for standard processing.
• When the Source is a Tier 2 Broker:
  • Move the lot to enhanced inspection protocols before allowing the parts into general inventory.

Step 2: broker risk mitigation (enhanced protocols)

When a component is sourced from the open market, especially Active components (ICs, Controllers) or high-value items, enhanced analysis is recommended:

• Destructive Analysis (Sample Testing):
  • Decapsulation (Decap): Expose the silicon die to verify that microscopic die markings match the OCM datasheet.
  • X-Ray: Check internal bond wire integrity, die size, and lead frame attach, comparing against a known-good sample.
  • XRF (X-Ray Fluorescence): Verify the physical lead finish (e.g. confirming RoHS compliance) matches the MPN specification.
• If the analysis result indicates a failure or high likelihood of counterfeit, initiate the Quarantine Protocol immediately.

Quarantine & disposition

If a part is identified as suspect counterfeit, handle it securely to prevent accidental use in production.

Containment (physical lockdown)

• The Action: Isolate the suspect parts. Avoid returning them to the vendor immediately, as this may allow the counterfeit parts to re-enter the global supply chain.
• The Storage: Secure the inventory in a segregated, clearly marked quarantine area (e.g. the MRB cage).
• The Tagging: Apply clear “NON-CONFORMING / SUSPECT” labeling to the materials.

Notification & reporting

• Internal Escalation: Notify the Supply Chain, Quality, and Leadership teams.
• External Reporting: Consider filing a report with organizations like GIDEP (Government-Industry Data Exchange Program) or ERAI once counterfeit status is confirmed by an independent lab.

The supplier feedback loop

• If a vendor supplies a confirmed counterfeit component, review their AVL status. They should typically be moved to a Disqualified or Blacklisted status.
• Initiate appropriate financial actions, such as credit holds, regarding pending invoices with that vendor while the investigation is ongoing.

Final Checkout: Counterfeit avoidance (AS5553)

Control Point	Engineering Requirement	Goal
Sourcing Rule	Prioritize Authorized Channels.	Target > 95% of spend
Broker Waiver	Executive/Engineering Approval for open market buys.	Process followed
Validation Requirement	Enhanced Testing (Decap/X-Ray) for high-risk sources.	Applied to Broker Lots
Visual Check	Microscope Inspection for physical anomalies.	Standard practice
Solvent Test	Chemical resistance check for remarking (MIL-STD H106).	Useful preliminary test
Disposition Rule	Industry Reporting for confirmed counterfeit parts.	GIDEP / ERAI Submission engaged