Random boot failures: ALERT! /dev/mmcblk0p1 does not exist

[pierre-pret]

We flash hundreds of Orange PI 3 LTS boards with stock Armbian Debian Bullseye via nand-sata-install to install it on the onboard eMMC storage.  Some boards after running for a week or more would randomly give this error and fail to boot:

 

Begin: Running /scripts/local-block ... done.
done.
Gave up waiting for root file system device.  Common problems:
 - Boot args (cat /proc/cmdline)
   - Check rootdelay* (did the system wait long enough?)
 - Missing modules (cat /proc/modules: ls /dev)
ALERT! /dev/mmcblk0p1 does not exist
(initramfs)

 

We can turn the board on and off as many times as we want, the error persists.  We can fix the problem by booting it from an Armbian SD again, mount the eMMC drive, then shut it down.  We don't change any files. For some reason only mounting it from eMMC make it boot fine again.  This has been confirmed with many boards.  Any idea what can be going wrong or what we can manually add to the image to prevent it?

 

 

[osmancik]

Yes I have encountered the same situation. Running a fsck finds some directories to lost+found folder. This looks like storage device fails for some reason.