eFAT: Improving the Effectiveness of Fault-Aware Training for Mitigating Permanent Faults in DNN Hardware Accelerators

Fault-Aware Training (FAT) has emerged as a highly effective technique for addressing permanent faults in DNN accelerators, as it offers fault mitigation without significant performance or accuracy loss, specifically at low and moderate fault rates. However, it leads to very high retraining overheads, especially when used for large DNNs designed for complex AI applications. Moreover, as each fabricated chip can have a distinct fault pattern, FAT is required to be performed for each faulty chip individually, considering its unique fault map, which further aggravates the problem. To reduce the overheads of FAT while maintaining its benefits, we propose (1) the concepts of resilience-driven retraining amount selection, and (2) resilience-driven grouping and fusion of multiple fault maps (belonging to different chips) to perform consolidated retraining for a group of faulty chips. To realize these concepts, in this work, we present a novel framework, eFAT, that computes the resilience of a given DNN to faults at different fault rates and with different levels of retraining, and it uses that knowledge to build a resilience map given a user-defined accuracy constraint. Then, it uses the resilience map to compute the amount of retraining required for each chip, considering its unique fault map. Afterward, it performs resilience and reward-driven grouping and fusion of fault maps to further reduce the number of retraining iterations required for tuning the given DNN for the given set of faulty chips. We demonstrate the effectiveness of our framework for a systolic array-based DNN accelerator experiencing permanent faults in the computational array. Our extensive results for numerous chips show that the proposed technique significantly reduces the retraining cost when used for tuning a DNN for multiple faulty chips.