Update 08/06: Intel published an additional note on Monday, confirming which SKUs are covered by the program. The full list of SKUs has been added to the article below, but it's essentially the 13600K/14600K and above – all of Intel's high-TDP desktop parts using the Raptor Lake B0 die.

Capping off an extensive (and expensive) week for Intel, the company has also announced that they are taking additional steps to address the ongoing chip stability issues with desktop Raptor Lake chips – the 13^th and 14^th Generation desktop Core processors. In order to keep owners whole, Intel will be extending the warranty on retail boxed Raptor Lake chips by two years, bringing the cumulative warranty for the chips to five years altogether.

This latest announcement comes as Intel is still in the process of preparing their major Raptor Lake microcode update, which is designed to mitigate the issue (or rather, further damage) by fixing the elevated voltage bug in their existing microcode that has led to the issue in the first place. That microcode update remains scheduled for mid-August, roughly a couple of weeks from now.

But until then – and depending on how quickly the update is distributed, even afterwards – there is still the matter of what to do with Raptor Lake desktop chips that are already too far gone and are consequently unstable. Intel’s retail boxed Raptor Lake chips ship with a 3 year warranty, which given the October 2022 launch date, would have the oldest of these chips covered until October of 2025 – a bit over a year from now. And while the in-development fix should mean that this is plenty of time to catch and replace any damaged chips, Intel has opted to take things one step further by extending the chips’ warranty to five years.

Overall, this is much-needed bit of damage control by Intel to restore some faith in their existing Raptor Lake desktop processor lineup. Even with the planned microcode fix, it remains unclear at best about what the long-term repercussions of the voltage bug is, and what it means for the lifespan of still-stable chips that receive the fixed microcode. In the best-case scenario, an extended warranty gives Raptor Lake owners a bit more peace of mind, and in a worst-case scenario, they’re now covered for a couple of years longer if the chip degradation issues persist.

One important thing to note, however, is that the extended warranty will only apply to boxed processors, i.e. Intel’s official retail chips. Intel’s loose chips that are sold by the tray to OEMs and certain distributors – commonly referred to as “tray” processors – are not covered by the extended warranty. While Raptor Lake tray processors do technically come with a three-year warranty of their own, Intel does not provide direct, end-user warranty service for these chips. Instead, those warranties are serviced by the OEM or distributor that sold the chip.

With the bulk of Intel’s chips going to OEMs and other professional system builders, Intel will undoubtedly need to settle things with those groups, as well. But with OEM dealings typically remaining behind closed doors, it’s unlikely we’ll hear about just what is agreed there. Regardless, whatever Intel does (or doesn’t do) to assuage OEMs and distributors, those groups will remain responsible for handling warranty claims for tray chips.

Finally, it should be noted that while today’s announcement outlines the two-year warranty extension, it doesn’t deliver the full details on the program. Intel expects to release more details on the extended warranty program “in the coming days.”

Intel’s full statement is below:

On Monday, Intel published an additional post outlining the specific SKUs covered by the extended warranty program. As the voltage/instability issues are thought to only affect high-TDP chips using Intel's Raptor Lake B0 die, which was used for both the 13th Gen and 14th Gen Core processors, the extended warranty program is also being setup to cover those processors specifically. In other words, only chips that are capable of being affected by the issue are receiving the extended warranty.

The rest of Intel's messaging is essentially unchanged from last week, telling customers of boxed processors to contact Intel directly, while tray processor owners need to contact their retailer/OEM.

Additional Details on Via Oxidation Issue

Separately, Intel’s community team also posted a brief update on the via oxidation issue that, although distinct from the current Raptor Lake instability issues, came into question at roughly the same time. Intel has previously stated that that issue is unconnected to the ongoing stability issues, and was fixed back in 2023. And this latest update offers a few more details on just what that manufacturing issue entailed.

Update 08/02: Patrick Moorhead has published a further tweet, clarifying that "Pat [Gelsinger] didn’t tell me l that there were yield issues. This was *my* interpretation." The text of the article has been updated accordingly to reflect this tweet, as well as Intel statements about accelerating their Ireland Fab 34 ramp-up.

Alongside Intel’s weak Q2 2024 earnings report and the announcement of $10 billion in spending cuts and layoffs for 2025, the company is also disclosing some new information about their chip deliveries over the first half of the year. A brief report, posted on X by analyst Patrick Moorhead and citing a conversation with Intel CEO Pat Gelsinger, revealed that Intel encountered a major production bottleneck on Meteor Lake earlier this year. The issue was significant enough to drive intel to take the extraordinary and costly step of accelerating their Ireland fab ramp-up in order to improve chip capacity.

It was a very rough Q2 for $INTC. And that guide... Thanks, @Pgelsinger, for the time to discuss.

It appears that there were yield/throughput issues on Meteor Lake, negatively impacting gross margins. When you have to get the product to your customers, and you have wafers to… pic.twitter.com/pHU66xvFe7

— Patrick Moorhead (@PatrickMoorhead) August 1, 2024

In a separate tweet posted several hours later, Moorhead then clarified that the yield issues mentioned in his first tweet were his interpretation of the matter, rather than something Pat Gelsinger had told him directly.

Decoding Moorhead’s dense tweets, fundamentally, Moorhead is questioning why Intel's Cost of Goods Sold (COGS) – how much the company's chips cost to produce – were on the rise with the launch of Meteor Lake.  The analyst surmised that yields and/or some other unexpected production bottleneck must be the case, as these are the typical issues that drive up chip COGS on a short-term basis like Intel has been experiencing.

And, judging from Intel's earnings call that took place after the initial tweet, Moorhead was right to an extent. Referencing the increased COGS, Intel CFO David Zinsner noted that Intel opted to ramp up its high-volume production in Ireland faster than initially planned. This increased Intel's capacity for Intel 4 (and Intel 3) capacity, but doing so also increased their costs, as wafers out of Ireland cost more in the near term.

Between Moorhead's report that OEMs have been receiving fewer Meteor Lake chips than they could use, and Intel's announcement that they accelerated the Ireland fab ramp-up, this is the first significant disclosure that Meteor Lake chips were, at least at some point, in unexpectedly short supply. Which in turn required Intel to take unexpected and extraordinary steps in order to improve chip production, at the cost of lower short-term profit margins and higher COGS.

The first of Intel's high-volume manufacturing (HVM) fabs to be equipped for the Intel 4 and Intel 3 processes, Fab 34 in Ireland is a critical element to Intel's cutting-edge product plans over the next couple years. Intel was not initially planning on relying so much on Fab 34 this soon – instead using their Oregon development fabs to do more of their Intel 4 & Intel 3 fabrication – but the company opted to ramp up at a faster pace. The benefit to Intel is that they get more fab capacity sooner, but it means they're incurring around $1 billion in costs now of what would have otherwise been spread out over further quarters during a more gradual ramp-up.

The net result was that, while Intel took a margin hit, it also allowed them to supply more Meteor Lake chips than they otherwise would have, even beating their own previous projections for Q2 shipments. Overall, Intel reported in their Q2 earnings that they’ve shipped 15 million “AI PC” chips since Meteor Lake’s launch, though the company doesn't break down how many of those were in Q2 versus Q1 and Q4'23. Still, according to Moorhead, this was fewer chips than OEMs would have liked to have, and they would have taken more chips if they were available.

COGS and Ireland ramp-ups aside, Moorhead also posits that some of Intel's capacity boost came from running “hot lots” of Meteor Lake – high priority wafer batches that get moved to the front of the line in order to be processed as soon as possible (or as reasonably close as is practical). Hot lots are typically used to get highly-demanded chips produced quickly, getting them through a fab sooner than the normal process would take. As a business tool, hot lots are a fact of life of chip production, but they’re undesirable because in most cases they cause disruptions to other wafers that are waiting their turn to be processed.

If true, running hot lots of Meteor Lake would be a significant development given the potential disruptions. At the same time, however, the situation with Meteor Lake is somewhat particular, as the Intel 4 process used for Meteor Lake’s compute tile (the only active tile made at Intel) is not offered to external foundry customers, or even used by other Intel CPUs (Xeon 6s all use Intel 3). So hot lots of Meteor Lake would have few other wafers to even jump ahead of for EUV tooling (Intel would certainly not put them ahead of high-margin Xeon products), while it's unclear how this would cascade down to any tools shared with Intel 7.

Intel, for their part, did not comment on Meteor Lake chip yields or hot lots in their earnings call.

In any case, Intel at this point is looking to turn around their troubled fortunes in the second half of this year. The company’s next-gen client SoC for mobile, Lunar Lake, is set to launch on September 3^rd. And notably, both of its active tiles are being built by TSMC. So Lunar Lake would be spared from any Intel logic fab bottlenecks, though it still has to go through Intel’s facilities for assembly using their Foveros technology. And there remains the thorny issue of higher production costs altogether, since Intel is paying for what's effectively the fully outsourced production of a Core CPU.

Amidst the backdrop of a weak quarterly earnings report that saw Intel lose money for the second quarter in a row, Intel today has announced that the company will be cutting costs by $10 billion in 2025 in an effort to bring Intel back to profitability. The cuts will touch almost every corner of the company in some fashion, with Intel planning to cut spending on R&D, marketing, administration, and capital expenditures. The most significant of these savings will come from a planned 15% reduction in force, which will see Intel lay off 15,000 employees over the next several months – thought to be one of Intel’s biggest layoffs ever.

In an email to Intel’s staff, which was simultaneously published to Intel’s website, company CEO Pat Gelsinger made the financial stakes clear: Intel is spending an unsustainable amount of money for their current revenues. Citing the company’s current costs, Gelsinger wrote that “our costs are too high, our margins are too low,“ and that “our annual revenue in 2020 was about $24 billion higher than it was last year, yet our current workforce is actually 10% larger now than it was then.” Consequently, Intel will be enacting a series of painful cuts to bring the company back to profitability.

Intel is not publicly disclosing precisely where those cuts will come from, but in the company’s quarterly earnings release, the company noted that it was targeting operating expenses, capital expenditures, and costs of sales alike.

For operating expenses, Intel will be cutting “non-GAAP R&D and marketing, general and administrative” spending, with a goal to trim that from $20 billion in 2024 to $17.5 billion in 2025. Meanwhile gross capital expenditures, a significant expense for Intel in recent years as the company has built up its fab network, are projected to drop from $25 billion to $27 billion for 2024, to somewhere between $20 billion and $23 billion in 2025. Compared to Intel’s previous plans for capital expenditures, this would reduce those costs by around 20%. And finally, the company is expecting to save $1 billion on the cost of sales in 2025.

Separately, in Intel’s email to its employees, Gelsinger outlined that these cuts will also require simplifying Intel’s product portfolio, as well as the company itself. The six key priorities for Intel will include cutting underperforming product lines, and cutting back Intel’s investment in new products to “fewer, more impactful projects”. Meanwhile on the administrative side of efforts, Intel is looking to eliminate redundancies and overlap there, as well as stopping non-essential work.

• Reducing Operational Costs: We will drive companywide operational and cost efficiencies, including the cost savings and head count reductions mentioned above.
• Simplifying Our Portfolio: We will complete actions this month to simplify our businesses. Each business unit is conducting a portfolio review and identifying underperforming products. We are also integrating key software assets into our business units so we accelerate our shift to systems-based solutions. And we will narrow our incubation focus on fewer, more impactful projects.
• Eliminating Complexity: We will reduce layers, eliminate overlapping areas of responsibility, stop non-essential work, and foster a culture of greater ownership and accountability. For example, we will consolidate Customer Success into the Sales, Marketing and Communications Group to streamline our go-to-market motions.
• Reducing Capital and Other Costs: With the completion of our historic five-nodes-in-four-years roadmap clearly in sight, we will review all active projects and equipment so we begin to shift our focus toward capital efficiency and more normalized spending levels. This will reduce our 2024 capital expenditures by more than 20%, and we plan to reduce our non-variable cost of goods sold by roughly $1 billion in 2025.
• Suspending Our Dividend: We will suspend our stock dividend beginning next quarter to prioritize investments in the business and drive more sustained profitability.
• Maintaining Growth Investments: Our IDM2.0 strategy is unchanged. Having fought hard to reestablish our innovation engine, we will maintain the key investments in our process technology and core product leadership.

The bulk of these cuts, in turn, will eventually come down to layoffs. As previously noted, Intel is planning to cut about 15% of its workforce. Just how many layoffs this will entail remains to be seen; Gelsinger’s letter puts it at roughly 15,000 employees, while Intel’s most recent published headcount would put this figure at closer to 17,000 employees.

Whatever the number, Intel is expecting to have most of the reductions completed by the end of this year. The company will be using a combination of early retirement packages and buy-outs, or what the company terms as “an application program for voluntary departures.”

Intel’s investors will be taking a hit, as well. The company’s generous quarterly dividend, a long-time staple of the chipmarker and one of the key tools to entice long-term investors, will be suspended starting in Q4 of 2024. With Intel losing money over multiple quarters, Intel cannot afford (or at least, cannot justify) paying out cash in the forms of dividends when that money could be getting invested in the company itself. Though as the long-term health of the company is still reliant on offering dividends, Intel says that the suspension will be temporary, as the company reiterated its “long-term commitment to a competitive dividend as cash flows improve to sustainably higher levels.” For Q2 2024, Intel paid out $0.125/share in dividends, or a total of roughly $0.5B.

Ultimately, the message coming from Intel today is that it is continuing (if not accelerating) its plans to slim down the company; to focus on a few areas of core competencies that suit the company’s abilities and its financial goals. Intel is throwing everything behind its IDM 2.0 initiative to regain process leadership and serve as a world-class contract foundry, and even with Intel’s planned spending cuts for 2025, that initiative will continue to move forward as planned.

On that note, cheering up investors in what’s otherwise a brutal report from the company, Intel revealed that they’ve achieved another set of key milestones with their in-development 18A process. The company released the 1.0 process design kit (PDK) to customers last month, and Intel has successfully powered-on their first Panther Lake and Clearwater Forest chips. 18A remains on track to be “manufacturing-ready” by the end of this year, with Intel looking to start wafer production in the first half of 2025. 18A remains a make-or-break technology for Intel Foundry, and the company as a whole, as this is the node that Intel expects to return them to process leadership – and from which they can improve upon to continue that leadership.

Sources: Intel Q2'24 Earnings, Intel Staff Letter