Overview / Main Features
The Toshiba Satellite A305-S6905 under analysis here is a 15.4 inch laptop computer powered by an Intel Core 2 Duo Mobile T6400 processor and GM45 Express Chipset. It comes configured with 3GB of RAM, 320GB hard disk drive and 8x DVD+/-RW optical drive. The Toshiba Satellite laptop also features an integrated webcam, ExpressCard 54 slot, on board media card reader as well as a notable eSATA I/O port along with prerequisite USB and IEEE1394.
Value Laptop PC
Pricing - Based on the configuration of the device under analysis, the Toshiba Satellite A305-S6905 retails for approximately $700 at the time of writing (Sept 2009).
Availability - Global (assumed)
For the purposes of this teardown analysis, we have assumed a lifetime production volume of 1 million 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 increment by an order of magnitude. Minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis.
Major Cost Drivers (Representing ~86% of total materials costs)
Intel - AW80577GG0412MA - CPU - Intel Core 2 Duo Mobile T6400, 2.0GHz, 2MB L2 Cache, 800MHz FSB, 45nm Process
Samsung - LTN154AT07 - Display Value Line Item - 15.4' Diagonal TFT LCD, WXGA, 1280 x 800 Pixels (16:10), 0.259mm x 0.259mm Pixel Size, 262K Colors, 300:1 Contrast Ratio, 220cd/m^2 Brightness, 8ms Response Time, Active Area: 331.2mm x 207.0mm
Hitachi - HTS543232L9SA00 - Hard Drive - 320GB, 2.5', SATA 1.5Gb/s, 5400RPM, 8MB Buffer
Samsung - M470T5663QZ3-CF7 - SO-DIMM DDR2-800 - 2GB, 256Mx64, 1.8V
Panasonic - UJ-880E - CD/DVD RW Drive - Slim Internal Type, Tray Load, SATA, 8X DVD±R, 6X DVD±R Dual Layer, 24X CD±R
PA3535U-1BRS - Battery - Li-Ion, 10.8V, 6000mAh
Intel - AC82GM45SLB94 - Northbridge - Graphics and Memory Controller Hub (82GM45)
Hynix - HYMP112S64CP6-S6 - SO-DIMM DDR2-800 - 1GB, 128Mx64, 1.8V
Intel - AF82801IBMSLB8Q - Southbridge - I/O Controller Hub (ICH9M)
Gold Circuit Electronics - 8-Layer - FR4, Lead Free
Intel - 512AN_MMW - WLAN Mini PCIe Module Value Line Item - 802.11a/b/g/n
Lite-On - AC Adapter - 19.5V, 3.95A
Keyboard Assembly - Injection Molded Plastic Keys, Mounted on Stamped Metal Backing Plate, w/ Interconnect Flex
Enclosure, Main, Top - Injection Molded Flame Retardant Polycarbonate, Clear Coated, Painted, Printed, w/ 22 Brass Inserts
Webcam PCB - Contains 1.3MP Camera Module, Sonix Camera Controller & Supporting Elements
Enclosure, Display, Top - Injection Molded ABS Polycarbonate, Clear Coated, Painted, Printed, w/ 11 Brass Inserts
Enclosure, Main, Bottom - Injection Molded Flame Retardant ABS Polycarbonate, w/ ESD/EMI Coating & 10 Brass Inserts
Cooler Assembly - Die-Cast Aluminum Plate, Copper Tube, Aluminum Fins
Total BOM Cost $511.86
What Is Not Included in our Cost Analysis
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.
OEM/ODM/EMS Relationships / Manufacturing
Toshiba's mobile PC manufacturing profile reflects a majority outsourced operational model. Approximately 79% of their product volume is sourced from EMS partners in Asia. Toshiba maintains manufacturing capacity domestically in Japan as well as facility in China. According to iSuppli's "Global OEM Manufacturing and Design Analysis - Compute Platforms, Toshiba's major contract manufacturers in 2008 are Compal, Inventec, Quanta and Pegatron (formerly Asustek) respectively.
Country of Origin / Volume Assumptions
Based on markings, the unit was assembled in China. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in China.
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 LCD display), 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
Invariably, laptop computers represent some of the more complex and electronically dense devices. Manufacturing costs for more densely configured devices in inevitably higher than such products as desktops where assembly is facilitated and costs reduced by not having to resort to more sophisticated, costly and complex systems for such things as interconnect (flex cable, PCBs, etc.). Furthermore, higher density PCBs cost inherently more, as typically this affects board layer counts, via structures and complexity, etc.
With that said, the overall component count on the Toshiba Satellite A305-S6905 came out to 1673 (excluding box contents), of which, 360 are mechanical in nature. This figure is on par with laptops in its category.
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. The cost of manufacturing is also, to some extent, decreased in this case because of assumed labor rate applied for China.
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.
Here is a summary of the major components used in the Toshiba Satellite A305-S6905 laptop design:
- Intel - AW80577GG0412MA - Core 2 Duo Mobile T6400
- Intel - AC82GM45SLB94 - Graphics and Memory Controller Hub (82GM45)
- Intel - AF82801IBMSLB8Q - I/O Controller Hub (ICH9M)
- SO-DIMM DDR2-800 - Samsung - M470T5663QZ3-CF7 (2GB, 256Mx64, 1.8V)
- SO-DIMM DDR2-800 - Hynix - HYMP112S64CP6-S6 (1GB, 128Mx64, 1.8V)
I/O & Interface
- Flash Memory Card Controller - Ricoh - R5C833
- Embedded Controller - Nuvoton - WPCE775LA
- Ethernet Controller - Realtek - RTL8102E
- Codec - Realtek - ALC268-GR
- LCD Panel - Samsung - LTN154AT07 (15.4' Diagonal TFT LCD, WXGA, 1280 x 800 Pixels, 16:10 format)
- Hard Drive - Hitachi - HTS543232L9SA00 (320GB, 2.5', SATA 1.5Gb/s, 5400RPM, 8MB Buffer)
- CD/DVD RW Drive - Panasonic - UJ-880E