In developing Cell, we were aiming for 90nm generation manufacturing. A major problem encountered at that time was a major increase in heat resulting from leak current (the phenomenon of current leakage from semiconductors). To increase the operating frequency, it is necessary to raise the operating voltage. However, expanding leak current causes power consumption to increase, triggering an exponential rise in the amount of heat generated. The amount of heat was substantially greater than we'd originally predicted. In fact, the technology had reached a major turning point, and the entire industry was focused on the problem of heat caused by leak current. The second half of the Cell design process was devoted almost entirely to battling with heat.
One way to achieve a fundamental solution to this problem was to reduce the operating voltage. However, because there is variation in the chips, we needed to find a way to control the voltage while also ensuring yield and reliability. Reducing the voltage also reduces power consumption, but if the voltage is too low, the transistor switching mechanism may not work properly, leading to errors after the product is on the market. However, the voltage is controlled on each chip in units of a several tens of millivolts, and the performance of each chip (the maximum voltage at which the chip can operate) is recorded individually during testing. We were able to set the optimal voltage by having the system read these records.
We also approached optimization from an application perspective. With a multicore system, there is always wait time. We added a function that used this wait time to suspend all circuits and cores that were not operating by controlling the clock supply. This is like turning out the lights in rooms or on entire floors where no people are present. Statistically, we can reduce heat by switching off these elements.
Unfortunately there was another dilemma. Games designed to use the full potential of the hardware are naturally going to be highly advanced. Therefore, playing such games leads to a decrease in unused circuits and an increase in power consumption. Several of us wrote a program that would block up the most pipelines, and we used that to establish Thermal Design Power (TDP).
Of course, there were many other challenges apart from heat, including semiconductor packaging, enhancing manufacturing yield, and software development. However, the development team was extremely motivated, and everyone worked from morning to night without noticing the time. Although our schedule was very tight, as engineers we were driven by the challenge of creating the world's most advanced technology. Each problem solved gave the team greater confidence to move on to the next step.
Sony, Sony Computer Entertainment, Toshiba and IBM all focused their total capabilities on the development of Cell. Differences in corporate cultures and philosophies made the project more interesting, although initially there were some problems over leadership. Yet when you work with people everyday in the same place, you gradually begin to understand their thinking. I personally learned a lot from this exposure to corporate cultures and development methods that were different from Sony's. I think that by combining each company's areas of excellence, we were able to create a better prototype chip.