I've been browsing your posts DBD79 and like them! A bit of hardware in the mix....
DeadTom is right, there is a certain level of redundancy built into some commercial grade chips. Also, very common in the 80s and 90s was offering two levels of something like a processor. For example, the 486 had an on-chip FPU. Chips which had a good FPU were sold as full 486s (486DX) while chips with defective FPUs were sold as 486SX. Intel would just disable the defective FPU and sell it on the cheap.
For some military and space-grade chips the redundancy can (and must) be very high. So obviously there would be a higher transistor count than normal, in addition to manufacturing processes such as silicon-on-sapphire.
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