Overview / Main Features
The Samsung LN-S4095D is a 40 LCD TV with full HD support, which means it supports up to 1080p resolution. It has a resolution of 1920 horizontal by 1080 vertical pixels and an image aspect ratio of 16:9. The device supports DTV resolutions of 480i, 480p, 720p, 1080i, and 1080p. It has a tuner which is capable of analog and full digital NTSC/ATSC with QAM. The LN-S4095D features two internal speakers capable of 10W output per channel with SRS TruSurround XT. A wide variety of input / output ports are present on the LN-S4095D, which includes HDMI, component, S-video, optical digital audio out, serial (9-pin D-Sub), and the standard analog / coaxial signals. The unit comes with a stand which can be detached. This model is priced at the higher end of the market within it's size range to target high-end buyers. Samsung can typically demand a premium in the market and also has the single largest LCD TV market share worldwide.
High-end LCD TV consumers.
The Samsung LN-S4095D appears to have been released in 2006, but conflicting reports show it released as early as Q2.
The 40" Samsung LN-S4095D LCD TV is currently available from multiple e-tailers at around $1250 (USD) or less in some cases, and is widely available in the US.
For the purposes of this teardown analysis, we have assumed a lifetime production volume of 120,000 units.
As a reminder, teardown volume production assumptions are primarily used for our cost analysis in terms of amortized NRE and tooling costs, especially for custom components specific to the model being analyzed (mechanical components especially). Unless assumed volumes are different by an order of magnitude, minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis because of this.
Samsung - LTA400HS-LH1 - LCD Display Unit - TFT, WUXGA, 40' Diagonal, 1920 x 1080 Pixels (16:9), 0.461mm x 0.461mm Pixel Size, 16.7M Colors, 1200:1 Contrast Ratio, 500cd/m^2 Brightness, 8ms Response Time, Active Area: 885.6mm x 498.2mm
Samsung Electro-Mechanics - IP-280135A - 300W
Electronic Cost Drivers - (From Main PCB)
Samsung Semiconductor - S5H2201A01 - DTV MPEG Decoder - ARM Powered
Trident Microsystem - SVP-LX - Video Processor - Digital Cinema Reality Engine, Support Full HD
Samsung Semiconductor - SDP42 - Scaler / Video Enhancer - Digital Natural Image Engine
Samsung Semiconductor - K4H511638C-UCCC - SDRAM - DDR, 512Mb(8M x 16Bit x 4 Banks), 2.6V
Samsung Semiconductor - K4D551638H-LC50 - SDRAM - GDDR, 256Mb(4M x 16Bit x 4 Banks), 200MHz, 2.35~2.7V
EtronTech - EM6A9320BI-5MG - SDRAM - DDR, 128Mb(1M x 32Bit x 4 Banks), 200MHz, 2.5V
Toshiba Semiconductor - TC90103AFG - Video Decoder - Color Decode w/ 3D Y/C Separation, For Multi-Standard System
Micronas - MSP4440K - Audio DSP - Demodulator, Decoder, and Baseband Audio
Mstar Semiconductor - MST3386M-LF-170 - HDMI Interface - HDMI1.0, Integrated Receiver, Rx Switch, 170MHz
Samsung Semiconductor - S3F84BBXZZ-QW8B - Microcontroller - 8 bit, w/ 64KBytes Flash, 2KBytes RAM, 10-Bitx8 A/D
Samsung Semiconductor - KFG5616U1A-PIB5 - Flash - OneNAND, SLC, 256Mb, 54MHz, 3.3V
Monolithic Power Systems - MP1583DN - DC-DC Converter - Step-Down, Adjustable, 3A
Mechanical Cost Drivers
Enclosure, Main, Front Bezel - Injection Molded ABS-Polycarbonate, Silkscreened, Clear Coat
Enclosure, Main, Rear - Injection Molded Flame Retardant High-Impact Polystyrene
Enclosure, Stand, Top - Injection Molded ABS-Acrylic Plastic, Clear Coat
Stand Base Support - Stamped / Formed Paint-Loc Steel
Enclosure, Main, Bottom Panel - Extruded Aluminum, Machined
Main PCB Cover - Stamped / Formed Paint-Loc Steel, Black Paint
Stand Mounting - Injection Molded Flame Retardant ABS
Materials and Manufacturing ~$939.03
The total materials and manufacturing costs reported in this analysis reflect ONLY the direct materials cost (from component vendors and assorted EMS providers), AND manufacturing with basic test. Not included in this analysis are costs above and beyond the material manufacture of the core device itself - cost of intellectual property, royalties and licensing fees (those not already included into the per component price), software, software loading and test, shipping, logistics marketing and other channel costs including not only EMS provider and the OEM's margin, but that of other resellers. Our cost analysis is meant to focus on those costs incurred in the manufacture of the core device and exceptionally in some circumstances the packaging and literature as well.
Country of Origin / Volume Assumptions
As with other Samsung LCD TVs we have analyzed in the US, and sourced in the US market, the product, based on markings, the unit was assembled in Mexico. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were sourced in Mexico as well based on the markings found on the parts. We assumed most of the PCBAs were populated in Korea and final assembled into the main enclosure in Mexico.
Country of origin assumptions relate directly to the associated cost of manufacturing, where calculated by iSuppli. In the cases of 'finished' sub-assemblies (such as can tuners), we do not calculate internal manufacturing costs, but rather assess the market price of the finished product in which case country of origin assumptions may or may not have a direct effect on pricing.
Remember also that labor rates are applied directly only to hand inserted components and systems in our bill of materials, and although regional assumptions do, these new rates do not have a direct effect on our modeled calculations of placement costs for automated SMD assembly lines. ""Auto" inserted components (such as SMT components) placement costs are calculated by an iSuppli algorithm which allocates a cost per component based on the size and pincount of the device. This calculation is affected by country or region of origin as well.
Design for Manufacturing / Device Complexity
The Samsung LN-S4095D LCD TV has a total component count of 3536 components (when itemizing the components from both power supplies and the can tuner, but not the display). This is a much higher component count than seen in other Samsung LCD TV models, including the recently analyzed LN-T4665F (Total component count of 2779).
If we account for the power supply and can tuners as 'single components', this brings the total count to 2755 components. Compare that to a comparable figure from the Samsung 46", and we get a total count of 1975. This represents nearly 40% more discrete components than the 46" model, almost all of which is explainable by a large difference in the passive components applied on the underside of the Main PCBs. This appears to come from the fact that the 46" model we recently analyzed appears to be of a more recent design vintage and appears to be more integrated, greatly decreasing the need for extra external components - mainly passives.
Whereas some LCDs and Plasma TVs analyzed in the past had many separate PCBs - the core functionality of this design all takes place on the single Main PCB. In addition to that PCB there are really only one other 'significant' PCBA the Power Supply PCB. We account for all of the sub-components of the power supply in our BOM, but produce a single cost line-item for the power supply as it is purchased, often from external suppliers, as a 'unit', and as such has it's own 'market' for price, independent of underlying component costs.
Those sub-assemblies that are an integral part of the LCD panel (CCFL inverter boards, and the LCD driver board) are not accounted for in this analysis as they are considered a sub-system of the LCD which is sold as a fully assembled unit, like a hard drive. The total discrete component count would increase significantly if this display were broken down into all of it's constituent components.
Component counts have a direct bearing on the overall manufacturing cycle times and costs, and also can increase or decrease overall yields and re-work. Our calculations of manufacturing costs factor counts and more qualitative complexities in the design. Note that manual labor has a much smaller effect on auto-insertion assembly lines (for the Main PCB, for example), where manufacturing costs are much more capital equipment intensive and driven by these investment costs.
This TV design, lie most other designs seen recently, is quite modular and falls into several large 'value' blocks, primarily the LCD panel (with CCFL backlight and other onboard drivers which constitute a single 'unit'), the Main PCB (only 1), and the power supply.
Samsung TV main PCBs (motherboards) seem to have much more core silicon and supporting components than lower end LCD TVs (such as the recently analyzed Vizio), but also have degreesof functionality, that while difficult to quantify or fully account for, are also greater than low-end units such as the Vizio. We believe that much of this added functionality revolves around added proprietary image processing in Samsung models.
Without doing a comprehensive reverse-engineering analysis, we can only say that the added functionality and therefore increased complexity in this Samsung design can be measured to some extent by metrics such as the I/O count, but also by the sheer number of chips as well as silicon surface area.
Here is a summary of the major components used in the Samsung LN-S4095D LCD TV design:
- Samsung - LTA400HS-LH1 - LCD Display Unit
- 40' Diagonal
- 1920 x 1080 Pixels (16:9) / WUXGA
- 0.46mm x 0.46mm Pixel Size
- 16.7M Colors
- 1200:1 Contrast Ratio
- 500cd/m^2 Brightness
- 8ms Response Time
- Active Area: 885.6mm x 498.2mm
- DNIE Image Processing Chipset
- Samsung / Trident Microsystems - STP10 / SVP-LX - Video Processor - Digital Cinema Reality Engine
- Samsung - SDP42 - Scaler / Video Enhancer
- MPEG Decoder - Samsung - S5H2201A01 - DTV, ARM Powered
- Microcontroller - Samsung - S3F84BBXZZ-QW8B - 8 bit, w/ 64KBytes Flash, 2KBytes RAM, 10-Bitx8 A/D
- Video Decoder - Toshiba Semiconductor - TC90103AFG - Color Decode w/ 3D Y/C Separation
- Samsung - DNVS303HH261A - ATSC Tuner Module(Contains core DTV Receiver - Samsung - S5H1409X01)
I/O & Interface
- Digital Audio System - ST Microelectronics - STA323W - 2.1-CH
- Microcontroller - Samsung - S3x94xx - 8-Bit, w/ ADC & PWM
- Audio DSP - Micronas - MSP4440K - Demodulator, Decoder, and Baseband Audio
- HDMI Interface - Mstar Semiconductor - MST3386M-LF-170 - HDMI1.0, Integrated Receiver, Rx Switch, 170MHz
- SDRAM - EtronTech - EM6A9320BI - 5MG - DDR, 128Mb, 4Mx32, 200MHz, 2.5V (Qty: 2)
- SDRAM - Samsung Semiconductor - K4H511638C-UCCC - DDR, 512Mb, 32Mx16, 200MHz, 2.6V (Qty: 2)
- SDRAM - Samsung Semiconductor - K4D551638H-LC50 - GDDR, 256Mb, 16Mx16, 200MHz, 2.7V (Qty: 2)
- Flash - Samsung Semiconductor - KFG5616U1A-PIB5 - OneNAND, SLC, 256Mb, 54MHz, 3.3V (Qty: 1)
- Samsung Electro Mechanics - IP-280135A - Multi-Output, 300W