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Discussions of Stick Failure and alternative file structures is now at [[Stick Layout]]
 
Discussions of Stick Failure and alternative file structures is now at [[Stick Layout]]
''Failure Modes''
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# Gets stuck at Fedora Login
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## With liveuser prefilled <br>I was able to repeatably create this failure when I was testing a version of schoolserver.py that had a typo in it.
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## With nothing prefilled <br> This error has successfully been replicated by Restarting multiple times.
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# Bug in initramfs /init detected. Dropping to a shell. Good luck! bash: no job control in this shell. <br> Stick abuse, like putting it through the washing machine, seems to precipitate this type of failure.
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# Freezes during use of an activity. Rebooting on the same computer doesn't help it still freezes on the same activity. One time we rebooted on a different computer and it worked.
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We don't know the root causes but we have plenty of theories.
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Sticks will always fail. There will always be multiple causes for failure.  This problem has to be addressed like a process engineering issue. Is stick failure a major cost in time or money? Find the largest cause of failure. Fix that to improve yield. Is stick failure a major cost in time or money? Find the the remaining largest cause of failure..... 
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This summer we had probably 10 sticks fail for 35 students.  That is a major cost in time and money.  The most common unrecoverable failure mode was stuck at Login.
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====We need a more robust files system====
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It has been shown that if you take a stick that is stuck at login and you copy over a fedora-overlay file from a working stick, the stick will boot again. Thus we are confident that the problem is corruption of the overlay file.
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''Next Steps'' - Try some alternate file structures.
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# Create a Fedora Full Install USB Stick, restart it a bunch of times and see if it does better.  How much space will the Fedora Full Install take?<br>So far its > 4GB http://wiki.sugarlabs.org/go/VMware#Full_Install_with_F11_Net_install_CD_to_USB_Stick
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# Create an Open Suse USB Stick, restart it multiple times and see if it fails. How much space does it use?
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''Background Links''
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Thread from the Fedora Forum: [[http://forums.fedoraforum.org/showthread.php?t=221719]]
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Here is an idea for an alternative USB Format: [[http://wiki.sugarlabs.org/go/Sugar_on_a_Stick/USB_format]]
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Also see Ticket 907 [[http://dev.sugarlabs.org/ticket/907]]
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A 2 GB USB is about $.60 more then a 1GB stick. If we need to compress less to get robustness its ok for us to require a 2GB USB.  A 4GB stick is about $2.50 more then a $1GB Stick.
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''Theories that have evidence against them''
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Dave Bauer was able to replicate the failure easily by restarting a Sugar stick. This means its probably not:
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* The Bulk Copier, Dave doesn't have one.
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* The older slower computers and USB 1 ports we are using at the GPA.
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====Sticks are damaged during formatting or burning====
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http://wiki.laptop.org/go/How_to_Damage_a_FLASH_Storage_Device [[http://wiki.laptop.org/go/How_to_Damage_a_FLASH_Storage_Device]]
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There was a detailed discussion thread back in February at: http://lists.laptop.org/pipermail/devel/2009-February/022987.html
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If we understood how to win and we had our own stick creation activity perhaps we would have less failures.
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====Sticks are of poor quality====
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Here is an explanation of two processes used to create USB sticks: http://www.solutiongrove.com/blogger/2008/09/08/there-are-two-type-of-usb-flash-memory-slc-and-mlc [[http://www.solutiongrove.com/blogger/2008/09/08/there-are-two-type-of-usb-flash-memory-slc-and-mlc]]
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====Sticks are being improperly removed====
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Yes they are, but its not at all clear to me that that correlates with the sticks that are failing.
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====There is a bug around restarting====
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It is very common to fail after a restart, the system forgets its supposed to go to Sugar.  See ticket 1069 [[http://dev.sugarlabs.org/ticket/1069]]
      
===Backup and recovery===
 
===Backup and recovery===
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