The latest news reports I found (last few months) said that Mediatek and Qualcomm are seeing defect rates of between 30% (TSMC) to 60% (Samsung) on their SoCs using these latest processes.
"news reports". There are more rumors sites on this an hard news sources.
At what stage of the rollout did they measure TSMC N4. TMSC 'at risk' N4 production doing 30% and Samsung "full production" doing 60% defect rate, then that is a "slam dunk" dump of Samsung. It is more than highly dubious that Qualcomm would switch a production run over to TSMC less than "half way" through the major part of the lifecycle without first doing some small-medium scale runs ( at least couple of hundred wafers ) at . In late '21 N4 was in "at risk" production ( started in Q3 '21 so Qualcomm could do a hasty port Q2-Q4 and catch then in of the 'at risk' segment.) . Qualcomm does the runs and is getting better than "production" at Samsung (which has another Quarter or two to find a fix to the problems. )
However, that doesn't mean that N4 is going to be a 30% defect rate in July-September of '22 ( which is more timeframe of where Snapdragon 8 plus gen 1 will ship ( Q3 '22). ) .
www.anandtech.com
On the diagram 7+ starts off lower defect rate than N7. And N6 starts off low also .
The TSMC pre HVM (high volume manufacturing) defect rate is much higher than when it gets to HVM. And even after the initial HVM market it still drops. Perhaps a bit of selective hand-waving but N6 ( with a 18% area shrink. Not 8 , but 18% ) doesn't show any wild increase in defect rates when it starts off. Even if N6 initial 'at risk' was incremetnally higher than 7+ starting point, it would still be below where N5 HVM started off at.
So N4 , a mild optimization of N5 (similar in relation of N6 to N7), shots off into the 30% zone for HVM defect rates? Errr, probably not. If it did then N3 is likely very screwed ( because an even bigger process 'formula' change.) Nor could Qualcomm afford to wait until port Q1 '22 to order up large wafer starts of N4 in the 2H of '22. These days nobody can just walk up to TSMC at the last minute and order up thousands of leading edge wafers.
So pretty good chance those "February '22" rumor leaks about TSMC vs Samsung defect rakes were from wafer runs done in 2021 from both shops. They caught early N4 before it got to HVM stage.
Apple is not going to accept a 30% defect rate on A16 - and that presumes A16 has a similar transistor density and complexity to Snapdragon 801. If it is more complex, then the defect rate could be even higher if they switched to that process.
It isn't the 801. The name scheme has now changed. It is just plain 8. Then a 'gen' then which gen number.
They have thrown a plus for this fab switch. Snapdragon 8 Plus gen 1 . Next year it will be SD 8 gen 2 . The 801 was released back in 2014. The transistor density of it is 28nm era; many Moore's law iterations ago.
Apple didn't have to ship the A16 in the 1H of '22 when N4 was closer to 'at risk' defect rates. So that doesn't really matter. Apple doesn't have to start to ramp the A16 production until May-June time frame.
Also if Qualcomm , Mediatek , and Nvidia are all ramping in 2H '22 on TSMC N4 then limiting the A16 orders to just the iPhone Pro makes more sense also. To some extent Apple may not have the option of doing the rest of the iPhone line up on N4 because there are not enough wafer starts to go around. If the A16 is only initially going into a more expensive phone, then 30% probably wouldn't be that bad. ( Pretty doubtful that it would stay at 30% long term, but Apple could have started ramp in April if necessary. )
Apple sticking with N5P would be to "save a buck" for some reason (e.g, sharing with some other Apple product. Couldn't get the 'volume' discount they wanted ,etc ) and discounts wrangled out of TSMC . 'at risk' production for N5P started back in Q4 '20. Volume production started in 1H '21. Why would Apple being going with a
year old process node in 2H of '22? The M2 also. Why roll it out with about a year old process tech? [ Unless it was suppose to ship out in Feb-March '22, and is backlogged. ]
It isn't because N4 is relatively 'bad' once a quarter or so into HVM production. N4 is meant to be a relatively easy "hop" from N5 (or N5P) to N4. Apple not taking it is more indicative of some problematic issue with Apple than TSMC. N3 and N4P aren't ready in time for A16.
Perhaps a corner case where Apple has extra early tape out access to N4P so start early, but doubtful that was a plan 2-4 years ago. N4 would have met the late 1H '22 start time. N4 has good chance of being a more long lived target so makes sense for A16 on N4 to trickle down into stuff like AppleTV , entry iPad , etc. As I've said previously going to N4 would get the die bloat, which over the long term has decent chance of making it more affordable to produce. The lifecycle of the SoC is across the whole set of Apple products they'll use it in. Not just the initial iPhone Pro product. ( an iPhone Pro 14 with better cameras , video recording, better AI/ML , etc. will sell. It isn't necessarily about single thread Geekbench porn scores. )
P.S. so the progression for Apple would go.
N5 : A14 , M1
N5P : A15
N4 : A16 , M2 (subset)
N3 : A17 , M3 (probably start very large expensive and work to small over time. Cover refreshed M2 subset last)
Those were all of the "in HVM" in May-June over 2020-2023 time frame . M-series is only picking up transistor density increases and skipping anything that is just a chance to bump clocks ( or no bump and just save power).
[ skipping non-transistor density increases is same thing the iPad Pro A--X sequence did over last couple of iterations. The bigger the die the longer the wait for a 'big enough to be interesting" density increase. Also the higher the priced product so moving at relatively much lower volume so fewer folks to spread yearly updates costs over. ]
P.P.S. I am not seeing much in the "news" about MediaTek's yields. Looks like there is presumption here that Mediatek's yields have to be Qualcomm's yields. Probably not. Mediatek did not do a hasty port ( SD 8+ gen 1 probably isn't highly optimized. They just wanted off of Samsung 'quickly' ). Also pretty good chance the die sizes are different also. Not going to be huge, but also not the same.