The ever increasing usage of microprocessor devices is sustained by a high volume production that in turn requires a high production yield, backed by a controlled process. Fault diagnosis is an integral part of the industrial effort towards these goals. This paper presents a novel cost-effective approach to the construction of diagnostic software-based test sets for microprocessors. The methodology exploits an existing post-production test set, designed for software-based self-test, and an

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... dy developed infrastructure IP to perform the diagnosis. An initial diagnostic test set is built, and then iteratively refined resorting to an evolutionary method. Experimental results are reported in the paper showing the feasibility and effectiveness of the approach for an Intel i8051 processor core.