Overview / Main Features
The DIGITURK DT-PHI7100 HD DVR Set-Top Box developed for the Turkish DVB satellite television provider. Overall, the DT-PHI7100 features a predominately ST-Microelectronics design at its core with ST-Microelectronics components totaling nearly 20% of the overall materials cost (second total cost after the hard disk storage drive). The DT-PHI7100 HD DVR set-top features a smaller 2.5-inch format hard disk drive. We typically expect to see 3.5 inch drives in DVR set-top boxes (and in fact, this the first time we've encountered a 2.5 in a set-top teardown). Since there is little price difference between 2.5" and 3.5" drives in this capacity, the OEM likely picked the smaller format for better energy efficiency.
Satellite Service (DVB standard) Providers
Pricing - Unknown (As with most satellite TV services, the cost of hardware is typically obscured by the overall service package contract)
Availability - Turkey (Assumed)
For the purposes of this teardown analysis, we have applied a lifetime production volume of approximately 500K 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.
Main Cost Drivers ~77% of Total Materials Cost
Hitachi - HCC545025B9A300 - Hard Drive - 250GB, 2.5', SATA 3Gb/s, 5400RPM, 8MB Buffer
ST Microelectronics - STi7105-OUC - Set Top Box Decoder - SoC, HD/SD, ST40 450MHz CPU, 32-Bit DDR/DDR2 Memory Interface
4-Layer - FR4, Lead-Free
Shenzhen Moso Power Supply Technology Co., LTD - XKD-Z4000IC12.0-48A - AC Adapter - 12V, 4.0A, 48W, w/ 6.6ft Cord
Elpida - E1116AEBG-8E-F - SDRAM - DDR2-800, 1Gb, 64Mx16, 1.8V (Qty:2)
ST Microelectronics - ST1S10PHR - Regulator - DC-DC Converter, PWM, Synchronous Step-Down, 3A, 900KHz, 2% (Qty:5)
Micron Technology - NAND01GW3B2CZA6 - Flash - NAND, SLC, 1Gb, 3V
Remote Controll Unit
Enclosure, Main, Bottom - Stamped / Formed Electro-Galvanized Steel, w/ 6 Pressed-In Threaded Metal Standoff
ST Microelectronics - STV0900BAB - Demodulator - Dual, DVB-S2/DVB-S, w/ DVB-S2 FEC
Enclosure, Main, Top - Stamped / Formed Electro-Galvanized Steel, Black Painted
ST Microelectronics - STV6110A - Tuner - Zero IF, 8PSK/QPSK, 950MHz-2150MHz, 3.3V (Qty:3)
Tyco Electronics(Dongguan) LTD - HDMI Cable - 8ft
Direct Materials + Manufacturing $109.74
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.
Country of Origin / Volume Assumptions
Based on the level of sophistication and function of the device, we made the assumption that the unit was assembled in Turkey. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in Turkey.
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 hard disk drive), 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 DT-PHI7100 set-top box under analysis here has an overall component count of 980 (excluding box contents), of which, 845 reside on the main PCB.
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 Turkey.
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 DT-PHI7100 Set-Top Box design:
- Hard Drive - 250GB, 2.5', SATA 3Gb/s, 5400RPM, 8MB Buffer
- Set Top Box Decoder - ST Microelectronics - STi7105-OUC
- Demodulator - ST Microelectronics - STV0900BAB; Dual, DVB-S2/DVB-S, w/ DVB-S2 FEC
- Digital Receiver - Microelectronics - STV0289; DVB-S2 / QPSKST
- Tuner - ST Microelectronics - STV6110A; Zero IF, 8PSK/QPSK, 950MHz-2150MHz, 3.3V
- SDRAM - Elpida - E1116AEBG-8E-F; DDR2-800, 1Gb, 64Mx16, 1.8V
- Flash - Micron Technology - NAND01GW3B2CZA6;NAND, SLC, 1Gb, 3V
- LNB Supply & Control IC - ST Microelectronics - LNBH24PPR; Dual, w/ Step-Up Converter, I2C interface
- LNB Supply & Control IC - ST Microelectronics - LNBH23LQTR;w/ Step-Up Converter, I2C interface
I/O & Interface
- Ethernet Transceiver - SMSC - LAN8710A-EZK
- Smart Card Interface IC - ST Microelectronics - ST8024CDR
- Audio/Video Buffer IC - ST Microelectronics - STV6437